System and method for circuit protector monitoring and management

ABSTRACT

A system and method for circuit protector monitoring and management.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 60/608,580 filed Sep. 10, 2004 and entitled Methodsand System for Circuit Protection, the entire disclosure of which ishereby incorporated by reference in its entirety.

This application also relates to U.S. application Ser. No. ______, filedSep. ______, 2005 and entitled Circuit Protector Monitoring Assembly.Kit and Method; U.S. application Ser. No. ______, filed Sep. ______,2005 and entitled Circuit Protector Signal Transmission, Methods, andSystems; U.S. application Ser. No. ______, filed Sep. ______, 2005 andentitled Circuit Protector Monitoring and Management System UserInterface Method, System, and Program; U.S. application Ser. No. ______,filed Sep. ______, 2005 and entitled Multifunctional Handheld ResponseTool, Method and System for Circuit Protector Management; and U.S.application Ser. No. 10/828,048, filed Apr. 20, 2004 and entitledWireless Fuse State Indicator System and Method; and U.S. applicationSer. No. 10/973,628 filed Oct. 26, 2004 and entitled Fuse StateIndicating and Optical Circuit and System, the complete disclosures ofwhich are hereby incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

This invention relates generally to circuit protection devices, and moreparticularly to systems for managing electrical systems includingcircuit protection devices.

Electrical systems typically include a number of circuit protectiondevices that protect electrical circuitry, equipment, and componentsfrom damage. Overcurrent protection devices, for example, areconstructed to physically open or interrupt a circuit path and isolateelectrical components from damage upon the occurrence of specifiedovercurrent conditions in the circuit. Known circuit protection devicesinclude devices such as fuses, circuit breakers, and limiters, which mayaddress overcurrent, overload, and short circuit conditions in anelectrical system, and other switching devices. As the size andcomplexity of electrical systems increase, the number of associatedcircuit protection devices also typically increases. Managing a complexelectrical system having a large number of circuit breakers, any one ofwhich may operate at any given time to isolate portions of the circuitryin the electrical system, is challenging.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic block diagram of an exemplary circuit protectormanagement system coupled to an electrical system.

FIG. 2 is a method flowchart for the circuit protector management systemshown in FIG. 1.

FIG. 3 is a schematic block diagram of an exemplary embodiment of acircuit protector and panel for the circuit protector management systemshown in FIG. 1.

FIG. 4 is a schematic block diagram of the status element shown in FIG.3.

FIG. 5 is a schematic block diagram of the reader element shown in FIG.3.

FIG. 6 is method flow chart of a first method of determining anoperation state of a circuit protector for the circuit protector andpanel shown in FIG. 3.

FIG. 7 is method flow chart of a second method of determining anoperational state of a circuit protector for the circuit protector andpanel shown in FIG. 3.

FIG. 8 is method flow chart of a third method of determining anoperational state of a circuit protector for the circuit protector andpanel shown in FIG. 3.

FIG. 9 is a schematic block diagram of a second embodiment of a circuitprotector and panel for the circuit protector management system shown inFIG. 1.

FIG. 10 is a schematic block diagram of a third embodiment of a circuitprotector and panel for the circuit protector management system shown inFIG. 1.

FIG. 11 is a schematic block diagram of a fourth embodiment of a circuitprotector and panel for the circuit protector management system shown inFIG. 1.

FIG. 12 is a perspective view of another embodiment of a circuitprotector and panel assembly for the circuit protector management systemshown in FIG. 1.

FIG. 13 is a schematic block diagram of the monitoring assembly shown inFIG. 12.

FIG. 14 is a perspective view showing internal parts of a module thatmay be used in the assembly of FIGS. 12 and 13.

FIG. 15 is a side elevational view of the monitoring assembly shown inFIG. 14.

FIG. 16 is a bottom exploded view of a circuit protector monitoringassembly kit that may be used in the assembly of FIGS. 12 and 13.

FIG. 17 illustrates a first version of the kit shown in FIG. 16.

FIG. 18 illustrates a second version of the kit shown in FIG. 16.

FIG. 19 is a perspective view of another embodiment of a circuitprotector monitoring module that may be used in the circuit protectormanagement system shown in FIG. 1.

FIG. 20 is a perspective view showing internal parts of the module shownin FIG. 19.

FIG. 21 is a perspective view of another embodiment of a circuitprotector module that may be used in the circuit protector managementsystem shown in FIG. 1.

FIG. 22 is a perspective view of the module shown in FIG. 21 coupled tocircuit protectors.

FIG. 23 is a schematic block diagram of a networked circuit protectionsignal transmission system that may be used in the circuit protectormanagement system of FIG. 1.

FIG. 24 schematically illustrates the signal transmission system shownin FIG. 23.

FIG. 25 is a method flowchart for the system shown in FIGS. 23 and 24.

FIG. 26 schematically illustrates a further embodiment of the systemshown in FIGS. 23-25.

FIG. 27 is an exemplary schematic block diagram of an exemplary circuitprotector management system utilizing the signal transmission system ofFIG. 23 and connected to an electrical system.

FIG. 28 is an exemplary site diagram of the electrical system shown inFIG. 27.

FIG. 29 is a system diagram of a further embodiment of the invention.

FIG. 30 is a simplified block diagram of an exemplary embodiment of theoverview and response dispatch system shown in FIG. 1.

FIG. 31 is an expanded block diagram of an exemplary embodiment of aserver architecture of the overview and response dispatch system shownin FIG. 30.

FIG. 32 is a flowchart illustrating exemplary processes utilized by theoverview and response dispatch system shown in FIGS. 30-32.

FIG. 33 is an example embodiment of a user interface displaying a logonscreen for a user of the overview and response dispatch system.

FIG. 34 is an example embodiment of a user interface displaying acircuit protector layout and overview.

FIG. 35 is an example embodiment of a user interface displaying acircuit protector layout in an alarm condition.

FIG. 36 is an example embodiment of a user interface displaying acircuit protector alarm management summary.

FIG. 37 is an example embodiment of a user interface displaying circuitprotector alarm management options.

FIG. 38 is an example embodiment of a user interface displaying acircuit protector alarm detail.

FIG. 39 is an example embodiment of a user interface displaying acircuit protector alarm forward.

FIG. 40 is an example embodiment of a user interface displaying circuitprotector alarm acknowledgement.

FIG. 41 is an example embodiment of a user interface displaying circuitprotector alarm clearance.

FIG. 42 is an example embodiment of a user interface displaying circuitprotector alarm annotation.

FIG. 43 is an second example embodiment of a user interface displaying acircuit protector layout and overview for a user of the overview andresponse dispatch system shown in FIGS. 30-32.

FIG. 44 is an example embodiment of a user interface displaying a zonealarm summary.

FIG. 45 is an example embodiment of a user interface displaying acircuit protector alarm summary.

FIG. 46 is an example embodiment of a user interface displaying acircuit protector alarm detail.

FIG. 47 is a schematic diagram of an exemplary circuit protectormanagement system including a circuit protector response tool.

FIG. 48 is a an exemplary method flowchart for responding to a circuitprotector alert using the circuit protector management system tool shownin FIG. 47.

DETAILED DESCRIPTION OF THE INVENTION

Exemplary embodiments of systems and processes that facilitatemonitoring and management of overcurrent circuit protection devices inelectrical systems, referred to herein as “circuit protectors”, andsystems and processes that facilitate rapid response to specifiedoperating conditions of the circuit protectors and associated circuitryare described below in detail. The systems and processes facilitate, forexample, detection of operated circuit protectors, notification toresponsible personnel of operated circuit protectors and their locationin the system for response and attention by authorized personnel,diagnostics and troubleshooting of circuit protectors and electricalsystems, and circuit protector inventory control and management forfacilities management. A technical effect of the systems and processesdescribed herein include at least one of organization and presentationof circuit protector information and electrical system data forfacilities management and system oversight, real time alarm conditiondetection and notification for circuit protector operation, automatedalert notification and summoning of personnel or site technicians toquickly reset and re-store downed circuitry due to operation of one ormore circuit protectors, archived installation and performance data ofthe circuit protectors and associated electrical system for diagnosticsand troubleshooting of electrical system perturbation events, andproactive management of electrical systems in anticipation of potentialcircuit perturbations.

A. Introduction

FIG. 1 is a schematic block diagram of an exemplary electrical system100 representative of the type of system that utilizes overcurrentcircuit protectors. In different embodiments, and as a few examples, theelectrical system 100 could be implemented as a battery poweredelectrical system for a vehicle, an AC or DC power distribution systemfor a building, industrial plant and/or control system, a communicationsnetwork, other system as those in the art will appreciate.

In the illustrated embodiment, the electrical system 100 includes apower supply or power supply circuitry 102, a circuit protector panel, acircuit protector holder, a circuit protector block or a circuitprotector cabinet (collectively referred to herein as “the panel 104”)coupled to the power supply 102 by a line L, and a number of electricalloads 106 operatively connected to the panel 104. The panel 104 includesone or more circuit protectors 108 that interconnect the power supply102 to the respective loads 106.

In various embodiments, the loads 106 may include electrical componentssuch as transformers, inductors, integrated circuits; equipment such asmachines, electrical motors and drive components, computers,programmable logic control systems; and sub-circuitry of the largerelectrical system 100. Additionally, the loads 106 may serve as asecondary power source to additional loads of the same or differentelectrical systems.

The circuit protectors 108 in an exemplary embodiment are overcurrentprotection devices, such as, for example, fuses, circuit breakers and/orswitches. Each circuit protector 108 is constructed to physically break,open, or interrupt a circuit path or current path between line and loadcircuitry and isolate the loads 106, for example, from the power supplycircuitry 102 to prevent damage to the loads 106 upon the occurrence ofspecified current conditions in the circuit, such as overcurrent,overload, and short circuit conditions. When such conditions occur, thecircuit protectors 108 prevent current flow between the power supplycircuitry 102 and the respective loads 106, protecting them frompotential damage attributable to current flow in such conditions. Thatis, in normal current conditions the circuit protectors 108 are in acurrent carrying or unopened condition completing an electricalconnection through between the power supply 102 and the loads 106, andin response to abnormal or unacceptable current conditions in thecircuit, the circuit protectors 108 change or operate to a non-currentcarrying state, sometimes referred to as an opened or tripped conditionbreaking the electrical connection between the power supply 102 and theloads 106.

While one circuit protector panel 104 is illustrated in FIG. 1, it isunderstood that the electrical system 100 may include a plurality ofcircuit protector panels 104 in different embodiments. The panels 104may be located in the same or different physical locations, and each ofthe circuit protectors 108 is associated with specific electrical loads106 of the system. While four circuit protectors 108 are illustrated inthe panel 104 for ease of illustration, it is contemplated that greateror fewer circuit protectors 108, including a single circuit protector108, may be employed in the panel 104. That is, the circuit protectorpanel 104 may be configured or adapted to connect a single circuitprotector 108 to the system 100, or alternatively may be adapted toconnect a plurality of circuit protectors 108 as those in the art willappreciate.

In complex electrical systems, many circuit protectors 108 are typicallyrequired in different panels 104 of various sizes and configurations.Also, complex electrical systems typically include various types andconfigurations of circuit protectors 108 to meet particular needs of theloads 106 and associated electrical subsystems. The combination of largenumbers of circuit protectors 108, assorted numbers of panels 104 indifferent locations, and various types of circuit protectors 108 in theelectrical system 100 presents difficult problems in locating operatedcircuit protectors 108 and resetting or restoring the circuitry when oneor more of the circuit protectors 108 in the electrical system 100operates to protect the associated loads 106 in the system 100.

As the size and complexity of electrical system 100 increases, thepotential locations of circuit protectors 108 in the system 100increases too. The panels 104 containing the circuit protectors 108 maybe located in different places in the electrical system 100, includingdifferent buildings, areas, compartments and portions of the electricalsystem site or facility. Therefore, when one or more circuit protectors108 operate to open a portion of the circuitry in the electrical system100, it can be a daunting task to locate which of the circuit protectordevices 110 has operated, and to take corrective action to reset orrestore affected circuitry and loads 106.

An elapsed time between operation of one or more circuit protectors 108and re-energizing of the associated circuitry to restore full operationof the electrical system 100 is significant in many applications. Forexample, in an industrial plant control system or office building, thetime in which affected machines or computers are unavailable due tooperated circuit protection devices amounts to lost productivity andeconomic loss. For virtually any electrical system, and especially forcritical electrical systems, minimizing the time and effort required tolocate operated circuit protectors 108 and to take corrective action isdesired.

When the circuit protectors 108 are circuit breakers, once theappropriate location of an operated circuit breaker has been identified,the breaker or breakers can generally be quickly reset. Locating thecorrect breakers, however, is not always a quick or easy task when thereare a large number of breakers in different locations or panels 104 inthe electrical system 100. To locate the operated breakers quickly,downed circuitry or equipment typically is matched with the appropriatebreakers of the system 100, which requires some detailed knowledge ofthe electrical system 100 that maintenance personnel may or may not haveat any given time. Alternatively, and probably more likely in mostcases, maintenance personnel systematically inspect all of the circuitprotector breakers in the electrical system to locate tripped breakers.Such an exercise is usually inefficient, except perhaps in situationswhere by mere chance the personnel starts the inspection in the area ofthe operated breakers. Also, locating tripped breakers can becomplicated when breakers in more than one location are tripped, and inthe case of faulty or inoperative breakers which are not tripped,restoring the circuitry of the electrical system 100 when one or more ofthe circuit protectors 108 operates can be extremely difficult and timeintensive.

When the circuit protectors 108 include fuses, operated fuses must belocated, replacement fuses must be obtained, and the operated fuses mustbe replaced to reset the circuitry of the electrical system 100. If areplacement fuse is on hand and the location of the operated fuse isknown, the fuse can typically be quickly replaced to restore thecircuitry. Locating which fuse or fuses has opened, however, andobtaining the proper replacement fuses, is not always easy. Fuses ofdifferent types may be located in various places throughout theelectrical system 100, and locating the proper replacement fuse from alarge inventory of different fuse types, whether on site or at a remotelocation, can be time intensive. As with circuit breakers, locatingoperated fuses can be complicated when more than one fuse operates, andlocating faulty fuses or improperly installed fuses in the electricalsystem 100 can be extremely difficult. Additionally, properly managing,maintaining, and replenishing a replacement fuse inventory to meetactual and anticipated needs of the electrical system 100 can bedifficult.

In addition, circuit protectors 108 tend to operate with little or noadvanced warning. Thus, troubleshooting the electrical system 100 and/ortaking preemptive action before the circuit protectors 108 operate isdifficult, if not impossible, in many electrical systems. Additionally,diagnosing the electrical system 100 to determine why or how certaincircuit protectors 108 operated is often an after-the-fact analysis andcan be speculative in nature.

B. The Circuit Protector Management System.

In an exemplary embodiment, and to alleviate these and otherdifficulties, each of the circuit protectors 108 is associated with astatus element 110 located internal or external to the circuit protector108. That is, the status element 110 may be located interior to orinside the circuit protector 108, on an external surface of or otherwiseoutside of the circuit protector 108, or even at another location at adistance from the circuit protector 108. As described further below, indifferent embodiments the status elements 110 may be implemented inelectronic form or be mechanically actuated to interface the statuselements 110 to the circuit protector management system 112. When acircuit protector 108 operates to open a circuit path in the electricalsystem 100, the associated status element 110 aids in identifying thecircuit protector so that the circuitry can be efficiently re-energizedwith minimal time delay.

Each of the status elements 110 of the circuit protectors 108 isresponsive to operation of the respective circuit protector 108, and inexemplary embodiments the status elements 110 transmit or communicatesignals or data to an circuit protector management system 112. Thestatus elements 110 in some embodiments may be used as data collectorsregarding operating conditions of the circuitry in the electrical system100, as explained further below.

In an exemplary embodiment, the circuit protector management system 112may include in whole or in part a communications device 114 incommunication with the status elements 110 of the circuit protectors108, a communications interface or link 116, an overview and responsedispatch system 118 in communication with the link 116, and an inventorymanagement system 120 in communication with the link 116 and/or theoverview and response dispatch system 118.

During operation of the electrical system 100, signals are sent from thestatus elements 110 of the circuit protectors 108, through thecommunications device 114 and the communication link 116, to theoverview and response dispatch system 118. The communications device 114allows the status elements 110 associated with the circuit protectors108 to communicate with the overview and response dispatch system 118and the inventory management system 120 via the communications interface116. In particular, when any of the circuit protectors 108 operates tointerrupt, break, or open a circuit path to one or more of the loads106, a signal is communicated from the respective identification element112 via the communications device 114 and the communication link 116 tothe overview and response dispatch system 118 and/or to the inventorymanagement system 120.

The overview and response dispatch system 118 and/or the inventorymanagement system 120 are, in turn, associated with an inventory 122 ofcircuit protectors and an automated or manual dispensing system 124 forstocking and replenishing the inventory 122 as the inventory is used.The inventory 122 may be located on site or at another location from theelectrical system 100.

In an exemplary embodiment, the communications device 114 is locatedproximate to the circuit protectors 108, either integrated into theconstruction of the panel 104 or in a location proximate to the panel104. The communications interface or link 116 may be a hard-wiredcommunications link, optical link, wireless communications link,satellite link, and equivalents thereof as explained further below.Additionally, the communications interface or link 116 may utilizeexisting infrastructure in the electrical system 100, and may operate,for example, using known power line frequency carrier technology orequivalents thereof over existing wires and conductors in the electricalsystem 100. Combinations of such communications links may likewise beprovided in different embodiments of the management system 112.

The communications link 116 may be a dedicated interface or link usedonly for circuit protector management purposes by the management system112, or may also serve other unrelated purposes and be used fortransmission of other signals, data and communications as desired.Communication between the communications device 114 and the overview andresponse dispatch system 118 may be established using known datatransmission protocols and network communication technologies such asDeviceNet and Datahiway protocols. Ethernet connections multiplexingcommunication schemes, wireless technologies, satellite transmissionschemes, equivalents thereof, and the like may also be used as those inthe art will appreciate.

While one communications device 114 is illustrated in FIG. 1, it iscontemplated that more than one communications device 114 may beemployed in the circuit protector management system 112. Multiplecommunications devices 114 may furthermore be employed in the same panel104 depending upon the number of circuit protectors 108 in the panel 104and the sophistication of the management system 112. In exemplaryembodiments, as further explained below, one communication device 114may be used to monitor multiple circuit protectors 108 and transmitinformation to the overview and response dispatch system 118.

In various embodiments, the overview and response dispatch system 118may be a network-based system, a personal computer, a computerworkstation, a programmable logic controller or other electroniccontroller, a processor-based hand held device or another electronicdevice or equivalent that may receive and process or interpret signalsfrom the link 116. In one embodiment, the overview and response dispatchsystem 118 may include a user display 126 to alert an operator ormaintenance personnel of an issue with the electrical system 100, suchas an operated circuit protector 108 which has broken a circuit path inthe electrical system 100.

In different embodiments, the inventory management system 120 is anetwork-based computer system, a personal computer, a computerworkstation, a processor-based hand held device, a programmable logiccontroller or an electronic controller or other electronic device whichreceives signals from the link 116 and/or the overview and responsedispatch system 118 and is capable of responding appropriately. Theinventory management system 120 may be integrated into the overview andresponse dispatch system 118 as desired, or may be a separate device inthe same or different location from the overview and response dispatchsystem 118. The inventory management system 120 is associated, directlyor indirectly, with the inventory 122, and is in communication with theautomated dispensing system 124. The automated dispensing system 124 maybe of a known type currently used in industrial and business facilitiesto provide uninterrupted access to supplies. Such automated dispensingsystems are commercially available and sometimes referred to as SmartInventory Systems. The automated dispensing system 124 electronicallyreceives and processes orders for circuit protection products so thatthe product orders are filled and the circuit protection products aredelivered to the inventory 122 with minimal delay. Alternatively, amanual inventory system may be employed to dispense and replenish thecircuit protection devices.

While one automated dispensing system 124 is shown in FIG. 1, it isappreciated that the overview and response dispatch system 118 andinventory management system 120 may communicate with more than oneautomated dispensing system 124 to obtain inventory products from thesame or different circuit protection product vendors, distributors orsuppliers as desired. Additionally, the overview and response dispatchsystem may communicate with known computerized maintenance managementsystem (CMMS), supervisory control and data acquisition (SCADA) systems,industrial control and automation systems, enterprise resource planning(ERP) systems, Electronic Data Interchange (EDI) systems, ManufacturingResources Planning (MRP) systems, and supply chain management systems inaddition to or in lieu of the inventory management system 120.

By virtue of the status elements 110 associated with the fuses 110, andas further explained below, the overview and response dispatch system118 may direct an operator or maintenance personnel to a preciselocation and to one or more specific circuit protectors 108 in theelectrical system 100 for resetting or restoring the circuitry.Additionally, the overview and response dispatch system 118 may locateproper replacement circuit protectors in the inventory 122 and directpersonnel to a precise location to obtain the proper replacement circuitprotectors, while contemporaneously ordering additional circuitprotectors via the manual or automated dispensing system 124 toreplenish the inventory 122 as it is used. Thus, the electronicmanagement system 112 can provide precise instruction to personnelregarding the circuit protectors 108 to minimize down time of theassociated load 108 for the operated circuit protector 112. The circuitprotectors 108 may therefore be attended to as efficiently as possible,and automated ordering of replacement parts for the circuit protectorinventory 122 ensures prompt replenishing of the inventory andeliminates error in inventory management. Factory automationtechnologies and equivalents thereof may be used to ensure thatreplacement circuit protectors are available for use and pinpoint theirlocation in a physical plant for retrieval by maintenance personnel, andinventory management is accomplished in an automated manner withouthuman intervention or action by maintenance personnel.

FIG. 2 is a flowchart of an exemplary method 130 for monitoring circuitprotectors 108 utilized the circuit protector management system 112shown in FIG. 1. The method 130 facilitates efficient re-energizingaffected circuitry in an electrical system 100 when one or more of thecircuit protectors 108 operates to isolate one portion of an electricalsystem 100 from another portion of the electrical system 100, such asisolating one or more of the loads 106 from the power supply 102.

In an exemplary embodiment, the method 130 includes providing 132 statuselements, embodiments of which are explained below, proximate to therespective circuit protectors of interest in the electrical system, andproviding 134 the electronic overview and response dispatch systemresponsive to the status elements. Once the status elements areinstalled 136, they may be used to monitor 138 an operating state of thecircuit protectors.

Based upon the sensed state of the circuit protectors, a data signal maybe transmitted 140 from at least one of the status elements to a remotedevice or location when one of the circuit protectors has operated toisolate a portion of the electrical system. The data signal, mayinclude, for example, an identification code and an address code toidentify the location of the operated circuit protector, and detailedinformation and instruction to appropriate personnel to reset or restorethe circuitry quickly and efficiently. When interpreted at the remotelocation by the overview and response dispatch system, the data signalmay be converted to an instruction to an operator or technician that mayinclude, for example, information regarding the location of operatedcircuit protectors, information needed to properly reset or restore thecircuitry affected by the operated circuit protectors, inventoryinformation for replacement circuit protectors needed to properlyrestore the circuitry, and information pertaining to operatingconditions of the circuitry for diagnostic and troubleshooting purposes.The instruction to personnel may further include specific informationregarding potential hazards in the location of the circuit protector,and information regarding precautions that should be taken and personalprotection equipment that should be utilized when responding to anoperated circuit protector.

In response to the data signals communicated 140 to the overview andresponse dispatch system, the overview and response dispatch systemgenerates 142 an alert and summons to responsible personnel, informingthem of the operated circuit protector and the location of the operatedcircuit protector. For example, the overview and response dispatchsystem may directly communicate with an operator, maintenance personnel,or others via a remote device such as a computer, pager, dispatcher, ahand-held device such as a personal digital assistant (PDA), personalinformation manager (PIM), or electronic organizer, cellular phone orequivalent device which is either networked with the overview andresponse dispatch system or in communication with the overview andresponse dispatch system and capable of reaching appropriate personnel.That is, the overview and response dispatch system may be active insteadof passive, and instead of simply providing an alert and waiting forhuman response, the overview and response dispatch system is capable ofactually seeking and directly contacting specific persons in multipleways, and summoning them to respond and intervene as needed to properlymanage the electrical system.

The alert and summons may be provided, for example, in an emailnotification, a fax notification, a pager notification, a web pagenotification, a voice notification, or other means. The overview andresponse dispatch system may wait 144 for acknowledgment of the alertand summons by one or more of the designated personnel, and if noacknowledgement is received, another alert and summons is sent.Optionally, the overview and response dispatch system may escalate 146the frequency or intensity of the alerts and summons depending uponresponsiveness of the designated personnel or actual operatingconditions of the electrical system. For example, if multiple circuitprotectors open at about the same time, a larger problem with theelectrical system could be implicated and the management system may moreurgently generate alarms, alerts and summons to address potentialproblems.

Optionally, the overview and response dispatch system may alsoautomatically undertake and initiate 148 other desired actions withouthuman intervention, such as activating auxiliary power to the affectedloads corresponding to specific machines or equipment, shutting down atrisk systems or loads corresponding to specific machines or equipment,saving key circuit data for analysis, etc. when the circuit protectors108 operate to open portions of the electrical system 100, andcommunicating such undertakings and actions to designated personnel forfurther evaluation and response.

More than one person may be contacted by the overview and responsedispatch system and summoned to help re-energize affected circuitry, forexample, by replacing operated fuses. Alerts and requests for action bydesignated personnel may be sent repeatedly from the overview andresponse dispatch system within specified time periods untilacknowledged by appropriate personnel, and escalated alerts and summonsmay be generated and special procedures implemented as appropriate todeal with different situations depending upon the sophistication of thecircuit protector management system 112.

Because the alert and notifications are sent more or lesscontemporaneously with the operation of the circuit protectors, andbecause the overview and response dispatch system actively attempts tofind, contact and summon personnel and provides complete informationneeded to re-energize affected circuitry, including at least the typeand location of operated circuit protectors, downed circuitry may bequickly re-energized and the full electrical system restored in as quicka time as possible. Automated alerts and summons may be sent around theclock without human intervention as needs arise. The informationpertaining to operated circuit protectors can be presented to the enduser in an easy to use tabular or graphical form in real time as thecircuit protectors operate, and the end recipient of the informationneed not gather additional information to complete the task ofre-energizing circuitry.

By actively seeking and contacting appropriate personnel, as opposed toa reactive system that is dependent upon human response, the overviewand response dispatch system is not dependent upon specific persons anddesignated personnel being in any specific location, such as aworkstation, terminal, or working area to receive an alert notificationof an operated circuit protector. Rather, the overview and responsedispatch system directly seeks out designated persons and contacts themwherever they may be found. Thus, should the persons or personnel beaway from a desk, workstation, terminal or working area during workingor non-working hours, the overview and response dispatch system iscapable of reaching them by other means and instantly notifying them ofoperated circuit protectors, rather than having to wait for them toreturn to receive an alert message at their desk, workstation, terminalor working area.

When used as data collectors, the status elements may facilitatemonitoring, troubleshooting, and diagnosis of the electrical system asthe circuit protectors are monitored 138 and signals are communicated140 to the overview and response dispatch system. Through monitoring andanalysis of such data, potential problems in the system may be moreaccurately identified and resolved, and more reliable operation of theelectrical system may be achieved. In such an embodiment, the alert orsummons generated 142 by the overview and response dispatch system mayinclude a warning or alarm to system operators or personnel toanticipate potential circuit opening events and circuit perturbationsthat may otherwise cause the circuit protectors to operate, potentiallyproviding time for preemptive measures to be taken before one or more ofthe circuit protectors operate to break the associated circuit paths inthe electrical system. The associated time, cost, expense andinconvenience of opened circuitry in the electrical system and theassociated time, cost, expense and inconvenience involved in resetting,restoring or re-energizing the circuitry due to operated circuitprotectors may therefore potentially be avoided in the first instancewith proactive management of the electrical system.

The overview and response dispatch system may further initiate 150 areplacement order to replenish, for example, a fuse inventory when theoperated fuse or fuses in the electrical system has been replaced.

C. The Status Elements and Circuit Protector Monitoring

It is contemplated that may different status elements and circuitprotector monitoring assemblies may be provided in the circuit protectormanagement system 102. Exemplary embodiments will now be described forillustrative purposes only. It is understood that other monitoringassemblies may be used in addition to the examples set forth below withequal effect.

1. Reader/Interrogator Monitoring Systems

FIGS. 3-8 illustrate exemplary embodiments of a first type of statuselement and circuit protector monitoring assembly 158 that may be usedin the circuit protector management system 112 and the method 130.

FIG. 3 is a schematic block diagram of the monitoring assembly 158including the circuit protector panel 104 and an exemplary circuitprotector 108. The panel 104 includes an area dimensioned to accommodatethe circuit protector 108, and conductive terminals 160. In theembodiment of FIG. 3, the circuit protector 108 is a fuse 162 and theterminals 160 are conductive fuse clips or equivalents thereof forestablishing line and load connections to the fuse 162.

In accordance with known fuses, the fuse 162 includes a protective bodyor housing 164 fabricated from an insulative or non-conductive material,conductive terminal elements 166, 168 coupled to the body 164, and aprimary fuse element 170 extending within the body 164 and electricallyconnected between the terminal elements 166, 168 to define a conductivecurrent path therebetween. The primary fuse element 170 is constructed,sized, and dimensioned to melt, disintegrate, vaporize, or otherwisestructurally open or interrupt upon the occurrence of a predeterminedovercurrent condition, such as an overload, overcurrent or short circuitcondition, to break or open the conductive current path and electricalconnection through the fuse 162 by preventing current flow between theterminal elements 166, 168. Opening of the primary fuse element 170 insuch a manner isolates one portion of an electrical system from anotherportion of an electrical system as explained above and protectselectrical components and equipment associated with the fuse 162 fromdamage which may otherwise result. Various types of fuse elements,fusible links, and assemblies are known that provide such overcurrentprotection, and the invention is not limited to any particular type orconfiguration of the primary fuse element.

In an illustrative embodiment, the fuse 162 is a cylindrical cartridgefuse including a cylindrical body 164 having a first end 172, a secondend 174, and a bore extending therebetween. The primary fuse element 170extends through the bore and is connected to the terminal elements 166and 168 in a known manner such as via conductive washers, soldering,welding, brazing, equivalents thereof or other acceptable mechanical andelectrical connection methods. In one embodiment, the terminal elements166, 168 are conductive ferrules or end caps and are attached to therespective ends 172, 174 of the body 164 in a known manner, such as withcrimping techniques. When the terminal elements 166, 168 are connectedto line-side and load-side electrical circuitry, such as the powersupply 102 and a load 108 as shown in FIG. 1, a current path is formedthrough the primary fuse element 170. While a cylindrical or tubularbody 164 is illustrated in FIG. 3, it is understood that other shapesand configurations of bodies or housings may be employed in alternativeembodiments, including but not limited to rectangular fuse modules.Likewise, a variety of terminal elements may be used in lieu of the endcaps illustrated in FIG. 3.

The status element 110 is electrically connected in parallel with orattached to the primary fuse element 170 and in one embodiment isinterior to the fuse body 164, although it is understood that in analternative embodiment the status element 110 may be located on an outersurface of the body 164 or elsewhere. In the illustrated embodiment, thestatus element 110 is connected to the terminal elements 166, 168 in aknown manner through a fine fuse wire 176 or other conductive materialhaving a much greater electrical resistance than the primary fuseelement 170. As such, only a very small portion of the current flowingthrough the fuse 162 flows through the status element 110, and thestatus element 110 may therefore monitor a relatively small current toindicate the state of the fuse 162 as described below.

In an exemplary embodiment, the status element 110 is a knowntransponder device 178, which communicates wirelessly with thecommunication device 114. In an exemplary embodiment, the communicationdevice 114 is also a transponder which functions as a reader orinterrogator device 180 as explained below.

The transponder device 178 and the reader device 180 communicate withone another to determine whether the fuse 162 is in an operational stateor whether the fuse 162 is in an operated state. As used herein, theoperational state refers to a current carrying or unopened conditioncompleting an electrical connection through the fuse, and the operatedstate refers to an opened condition breaking the electrical connectionthrough the fuse. Still further, the transponder device 178 maycommunicate, in addition to the opened or unopened state of the fuse,other data and information of interest regarding the operation of theelectrical system 100.

For example, in one embodiment, the transponder device 178 collectscurrent, temperature and/or voltage data over time experienced by thefuse 162. Current and voltage readings, for example, may be obtainedwith known sensor elements measured across, for example, a shunt withinthe fuse 162 or by other equivalent techniques known in the art.Alternatively, temperature sensors may also be used to monitor operatingtemperatures of the fuse housing 164, terminal elements 166 and 168, orthe fuse clips 160. By comparing sensed temperature readings ortemperature determinations of conductive portions of the fuse 162 or thefuse clips 160 to empirically determined temperatures corresponding topredetermined current levels and intensities, the operating currentthrough the fuse 162 may be deduced and communicated to the overview andresponse dispatch system 118 via the reader device 180. Current, voltageand temperature readings may be input to the transponder device 178 forcommunication to the reader device 180.

In an exemplary embodiment, the transponder device 178 and reader device180 communicate wirelessly via radio frequency and the system operatesin accordance with known radio frequency identification (RFID) orequivalent systems. As such, and as those in the art may appreciate, thetransponder device 178 may be an RFID identification tag or equivalent,sometimes referred to as an RF chip, and the reader or interrogatordevice 180 is an RFID reader or an interrogator. Thus, the RFtransponder device 178 and reader device 180 operate on close proximityelectromagnetic or inductive coupling of the transponder device 178 andthe reader device 180 to communicate with one another, or alternativelyoperates using propagating electromagnetic waves. It is contemplated,however, that other forms and types of wireless communication may beutilized in lieu of RFID communication, including but not limited toinfrared communication.

In an exemplary embodiment, the transponder device 178 and theinterrogator device 180 communicate via an air interface over apredetermined radio frequency carrier, for example, 100-500 kHz, andmore particularly, at about 125 kHz. It is understood, however, thatother frequency carriers may be employed per applicable RFID standards.Also, it is recognized that data transmission rates between thetransponder device 178 and the reader device 180 are impacted by theselected carrier frequency for signal transmission. That is, the higherthe frequency, the higher the transmission rate between the devices.

The operating range or distance of communication between the readerdevice 180 and the transponder device 178 is dependent upon the powerlevel of the devices, which may be, for example from 100-500 mW or asdictated by applicable regulations. The range is principally affected bythe power available at the reader device 180 to communicate with thetransponder device 178, the power available within the transponderdevice 178 to respond, and environmental conditions and the presence ofstructures in the operating environment. In one embodiment the powerlevel of the transponder device 178 is much less than the power level ofthe reader device 180. Generally, the transponder device 178 is selectedto meet desired specifications and objectives for a particular operatingenvironment.

Referring now to FIG. 4, the transponder device 178 is schematicallyillustrated. The transponder device 178 may include a processor 182, anmemory 184 which in various embodiments may be read-only memory (ROM),random access memory (RAM), or a non-volatile programming memory, suchas electrically erasable programmable memory (EEPROM), or equivalentsthereof depending on the sophistication of the transponder device 178,and an antenna 186. In one embodiment, the processor 182 communicates,via radio frequency, with the reader device 180 when interrogated by thereader device 180, and the antenna 186 senses a data field generated bythe reader device 180 in operation. The antenna 186 also communicates ortransmits a response to the reader device 180 in a known manner. Thememory 184 is used for data storage of, voltage, current and/ortemperature readings for example, and storage for executableinstructions and responses to the reader device 180.

Referring now to FIG. 5, the reader device 180 is schematicallyillustrated. The reader device 180 includes a processor 190, an antenna192, and a memory 194. The processor 190 communicates, via radiofrequency, with the transponder device 178 and the antenna 192 is usedto send signals to the transponder device 178 and receive signals fromthe transponder device 178 in operation. The memory 194 may be read-onlymemory (ROM), random access memory (RAM), or non-volatile programmingmemory, such as electrically erasable programmable memory (EEPROM), andtheir equivalents depending on the sophistication of the reader device180. The memory 194 may include executable instructions and controlroutines for execution by the processor 190.

Referring now to FIGS. 3-5, the reader device 180 may mounted to thepanel 104 in the vicinity of the fuse 162. Periodically, the readerdevice 180 sends a signal, sometimes referred to as an interrogation, tothe transponder device 178 associated with the fuse 162. Specifically,the reader device 180 interrogates the transponder device 178 viawireless communication over an air interface such that a transmissiondata field of the antenna 192 of the reader device 180 interacts with atransmission data field of the transponder device antenna 186. Inresponse to the interrogation, the transponder device 178 answers thereader device 178. Depending upon the sophistication of thecommunication protocol and the relation of the transponder device to theprimary fuse element 170 of the fuse 162, the operational state of thefuse 162 may be determined in a variety of ways by the processor basedreader device 180. The operational state of the fuse 162 may bedetermined by a response, or lack of response, from the transponderdevice 178 to an interrogation by the reader device 180.

For example, and in an exemplary embodiment, the transponder device 178is a passive radio frequency transmitter, and relies upon a transmissiondata field generated by the reader device 180 for power to respond tothe reader device 180. FIG. 6 illustrates an exemplary method 198 forsuch an embodiment to determine the operation state of the circuitprotectors.

Referring now to FIG. 6, the processor based reader device may beprogrammed to poll 200 the circuit protector status elements in thesystem and await 202 a response from the transponder devices. Responsesreceived to interrogations in the polling process may be interpreted 204and provided, output or communicated 206 to the overview and responsedispatch system. For example, in one embodiment any signal received 202from a transponder device in response to an interrogation by the readerdevice may be taken as an indication that the primary fuse element ofthe associated fuse is operational. In an embodiment similar to FIG. 3,when the primary fuse element 170 opens the entire current would bedirected to the transponder device 178, and if the transponder device178 is selected so that the current destroys or renders the transponderdevice 178 inoperable, the transponder device 178 could not function torespond after the fuse 162 has opened. Thus, the fact that a responsewas received in such a scenario indicates that the primary fuse element170 has not opened, and the operational status of the fuse 162 may beaccordingly provided 206 to the overview and response dispatch system.The status elements may be polled repeatedly in such a system andresponses collected to monitor the larger electrical system.

The method 198 may be employed in an embodiment where, through strategicselection of the transponder device 178 and with strategic connection ofthe transponder device 178 to the fuse 162, the transponder device 178may withstand opening of the primary fuse element 170 and determine theopening of the primary fuse element 170 via, for example, current orvoltage sensing of the electrical circuit through the fuse 162 ortemperature sensing of the fuse clips 160 or the terminal elements 166,168 of the fuse 162. In such an embodiment, the transponder device 178may respond in a first manner when the fuse 162 is in an operationalstate and respond in a second manner different from the first when thefuse 162 is in a non-operational state breaking the circuit through thefuse 162 when the fuse 162 has operated. The reader device may beprogrammed to distinguish between the two manners of response, andcommunicate 206 the status of the fuses to the overview and responsedispatch system.

In another exemplary method 210 illustrated in FIG. 7, the reader device180 may poll 212 the status elements and await responses 214 from thetransponder devices associated with the fuses. A lack of response fromthe any of the transponders may be used to indicate that the associatedfuse has opened, and the operated status of the fuse may be communicated216 to the overview and response dispatch system. If a response isreceived 214, the operational status of the fuse is communicated to theoverview and response dispatch system.

The method 210 could likewise be used in an embodiment wherein atransponder device is merely physically located in proximity to theprimary fuse element of a fuse without being electrically connected tothe terminal elements of the fuse, or without being connected to theprimary fuse element. In such an embodiment, heat and electrical arcingassociated with opening of the primary fuse element would damage thetransponder device and prevent it from responding to an interrogation.Thus, if no response is received from a given transponder device, it maybe presumed that the associated fuse has opened.

Using either of the methods 198 or 210, the reader device 180 mayinterrogate the transponder devices 178 of multiple fuses 162 in thepanel 104 and determine, based upon the type of responses received,which, if any, of the fuses 162 in the panel 104 have operated to opencircuits to the loads 106. In a more advanced communications protocol, aresponse from a transponder device 178 may be decoded by the readerdevice 180, thereby allowing communication of specific data stored inthe transponder device memory 184 to be communicated to the readerdevice 180. For example, the data may include one or more of thefollowing exemplary data information: an identification code for aspecific fuse 162 in the system; a type or size code for the fuse 162; alocation code for the panel, block or holder associated with the fuse162 in the electrical system 100; an identification code for thespecific panel 104 associated with the fuse 162; an inventory code forthe fuse 162; a manufacturing date of the fuse 162 or other informationas desired; and even data pertaining to current, voltage and temperaturecharacteristics over time may be stored in the memory 184 of thetransponder device 178. Thus, by collecting operating data, thetransponder device 178 could be of aid in troubleshooting the electricalsystem, and could be helpful to detect improperly installed fuses ormalfunctioning fuses by denoting abnormal or unexpected current, voltageor temperature characteristics of the fuse 162 in operation.

Data of interest with respect to the electrical system and the loadconnected to the fuse 162 may also be sensed by calibrated transducersand communicated to the transponder device 178 and/or the reader device180. For example, data may be collected and communicated relating tovibration and displacement conditions for electric motors, stress/strainmeasurements and readings, acoustical emissions and noise readings,thermal imagery and thermalography readings, resistance readings,pressure readings, and humidity readings.

In another embodiment, and as illustrated in FIG. 8, another method 220for determined the status of circuit protectors is provided. The method220 may be used, for example, when the transponder device 178 is anactive radio frequency transponder, and is powered by an onboard powersupply, such as a battery 222 (shown in phantom in FIG. 4), oralternatively, is powered by the electrical current passing through asecondary fuse link of the fuse as shown in FIG. 3. As such, thetransponder device 178 is capable of storing data and transmitting thedata to the reader device 180 when interrogated. That is, in such anembodiment the transponder device 178 is a read and write device and iscapable of advanced functions, such as problem diagnosis andtroubleshooting.

The processor 190 of the reader device 180 may collect 223 operatingdata such as current, voltage or temperature conditions of the circuitprotector, process the collected data, and compile 226 the data andinformation relating to the state of fuses 162 in the panel 104 asinterrogations are made and as replies are received, and the data andinformation is then stored 228 in the memory 194 of the reader device180. Such data and information stored in the memory 194 may bedownloaded, transmitted, or otherwise communicated 230 to the overviewand response dispatch system 118 and/or the inventory management system120 using the communication link 116. The data may be communicated 230to the overview and response dispatch system on a periodic basis or asevents of interest occur, including but not limited to overcurrent,overvoltage, and temperature overlimit conditions, and the method 220does not require polling or interrogation from the reader devices tooperate

Utilizing the method 220, the overview and response dispatch systemprocesses and stores the information and data for evaluation by a userfor analysis, and the overview and response dispatch system may beprogrammed to alert a user when specified data is obtained according tothe method 130. As such, and for example, a user may be alerted when oneor more of the fuses 162 experiences voltages, currents, or temperaturesthat are not within normal or expected operating ranges, and themanagement system 112 may therefore provide some advanced warning of apotential problem that may cause one or more fuses 162 to operate andopen circuitry to the loads 106. If possible, corrective action may thenbe taken to manage the electrical system 100 to avoid operation of fuses162 and the resultant disconnection of the respective electrical loads106. The method 220 may also identify improperly installed ormalfunctioning fuses, and permit diagnosis and troubleshooting of theelectrical system 100 apart from issues relating to the circuitprotectors.

By virtue of the circuit protector management system 112, and accordingto any of the aforementioned exemplary methods 198, 210 and 220, anyfuses 162 that are opened and require replacement may be identified,together with other data of interest regarding the fused electricalsystem 100. Improperly installed fuses, the presence or absence of fusesin the panel 104, or malfunctioning units or panels 104, may likewise bedetected and diagnosed with appropriate programming of the transponderdevice 178, the reader device 180, and the overview and responsedispatch system 118.

Data from the overview and response dispatch system 118 may likewise betransferred to the reader device 180, and the transmitted data may beused, for example, to match responses from selected transponder devices178 with specific fuses 162 in the panel 104. Such data may be used togenerate interrogatories to specific fuses 162 of a electrical systemfor diagnostic or troubleshooting purposes. In such an embodiment thetransponder devices 178 of the fuses 162 may be programmed to ignorecertain interrogatories and to respond to other interrogatories from thereader device 180. Further, the transponder device 178 of the fuses 162may be programmed to respond differently as different interrogatoriesare made. For example, a transponder device 178 may send a very basicresponse to a basic interrogatory, or a detailed response includingsupporting data for a more advanced interrogation. Also, in such asystem, the reader device 180 may be used to confirm the status ofcertain fuses 162 in the panel 104 with different interrogations andcollecting certain information before notifying the overview andresponse dispatch system 118 of an operated fuse 162.

Having now described some exemplary embodiments of status elementtransponder and reader/interrogation elements interfacing with theoverview and response dispatch system 118, programming of the systemcomponents to achieve desired outputs for monitoring the status of thefuses 162 and the associated electrical system 100 may be providedconventionally.

2. Transmitter and Transponder Monitoring Systems

FIG. 9 is a schematic block diagram of another type of status elementand circuit protector monitoring assembly 238 that may be used in thecircuit protector management system 112 and the method 130.

The assembly 238 includes a circuit protector 108 in the form of a fuse240 and panel 104. The fuse 240 is similar to the fuse 162, but includesa status element 110 in the form of a transmitter 242, and acommunications device 114 in the form of a transponder device 244 whichreceives signals from the transmitter 242 and transmits or otherwisecommunicates signals and data to the overview and response dispatchsystem 118. The transmitter 242 may be an active device and transmitsdata, including but not limited to voltage, current or temperature data,to the transponder 244 on a periodic basis. In turn, the transponder 244communicates the data to the overview and response dispatch system 118via any of the aforementioned communication technologies. Thus, thetransmitter 242 of the fuse 240 is active and the transponder 244 isgenerally reactive in transmitting data to the overview and responsedispatch system 118. When the primary fuse element 246 within the fuse240 opens to break the circuit through the fuse 240, the transmitter 242detects the operated fuse and opened circuit by any of theaforementioned sensing methods.

Once an operated fuse 240 is detected, the transmitter 242 sends asignal to the transponder 244. In turn, the transponder 244 signals theoverview and response dispatch system 118 of the operated fuse, and theoverview and response dispatch system 118 takes appropriate action tonotify personnel and instruct personnel regarding the location of areplacement fuse, pinpoint the identity of the operated fuse, and ordera replacement fuse. Global positioning technology may be employed todetermine the precise location of operated and replacement fuses 240 andto avoid any uncertainty or confusion on behalf of personnel in locatingthe operated fuse or the replacement fuse.

In one embodiment, the transmitter 242 and responder 244 are implementedas application specific integrated circuitry and communicate wirelesslywith one another according to known RFID, infrared or other wirelesstransmission techniques and equivalents thereof. While wirelesscommunication is believed to be advantageous to avoid point-to-pointconductive paths between the transmitter 242 and responder 244, it isunderstood that in alternative embodiments, other known transmitting andreceiving devices and methods may be employed. An onboard power supply,such a battery 245 may be employed in the transmitter 242 to sendcommunications after the fuse 240 has operated, or alternatively, anenergy storing component 247, such as a capacitor, may be employed inthe fuse 240 to power communications within a short time after the fusehas operated. Still further, switching devices may be used to connectthe transmitter 242 to an alternative power source such as a battery,backup power supply, or other circuit of the electrical system after thefuse 240 has operated and the circuit through the fuse 240 is broken topermit the transponder 244 to communicate with the overview and responsedispatch system 118. A power harvest device, including rechargeablebatteries and the like that store energy when not in use, may be also beutilized for the energy storage component 247 in addition to or in lieuof the battery 245.

It is contemplated, however, that in an alternative embodiment, anabsence of a signal transmission from the transmitter 242 could be takenas an indication that the fuse 240 has opened and the transmitter 242 nolonger has power, and the overview and response dispatch system 118could respond appropriately without an active signal transmission thatthe fuse 240 has opened. Thus, for example, if no transmission wasreceived from the transponder 244 within a given time frame, thetransponder could signal the overview and response dispatch system thatthe associated fuse has opened.

In a further embodiment, a combustible fuse state indicator 248 and anoptically activated indicating circuit 249 may be provided that sensesan emission of light in the indicator 249 when the indicator 248 isignited, combusted, and consumed. Once light is sensed when thecombustion occurs, the light may be converted into an electrical signalthat may be input to the transmitter 242 for wireless transmission to aremote location. A combustible fuse state indicator and opticallyactivated indicating circuit are described in detail in commonly ownedU.S. patent application Ser. No. 10/973,628, the disclosure of which isherein incorporated by reference.

It is understood that more than one transmitter 242 may communicate withone or more transponders 244 so that multiple circuit protectors can bemonitored The transponders 244 may be integrated into the panel hardwareor be separately provided components. Multiple transponders 244 may beemployed in a single panel 104 depending on the number of fuses 240 inthe panel 104 or the sophistication of the circuit protector managementsystem 112.

3. IC Card Monitoring Systems

FIG. 10 is a schematic block diagram of another type of status elementand circuit protector monitoring assembly 250 that may be used in thecircuit protector management system 112 and the method 130.

As shown in FIG. 10, the assembly 250 includes a circuit protector 108in the form of a fuse 251 and panel 104 for the circuit protectormanagement system 112 shown in FIG. 1 and the method 130 shown in FIG.2. The fuse 251 is similar to the fuse 162 shown and described inrelation to FIG. 3, but includes a status element 110 in the form of asmart card 252.

In an exemplary embodiment, the smart card 252 may be a thin filmsubstrate device that contains an embedded integrated circuit (IC)having data transmission, storage and processing capability, and thecard 252 is sometimes referred to as a chip card or IC card. In oneembodiment, the smart card 252 is a microprocessor card or equivalentthereof and contains, for example, self-executable Java code sometimesreferred to as Applets developed on a Java Card Applications Environmentusing the Java programming language. New code can be downloaded into thesmart card 252 to change the circuit protection properties of the Appletand update or change the information on the card 252. Java Cardtechnology specifications and development kits are available from SunMicro Systems and the cards may be configured or adapted accordingly.

Circuit protection logic on the smart card 252 can be used to storeinformation and add, delete, and manipulate information in its memory.The smart card 252 may be used in combination with a chip fuse 254connected in parallel with the primary fuse element 256 of the fuse 251,and the smart card 252 is used to monitor the current and temperature ofthe chip fuse 254 to detect operation of the primary fuse element 256.When the primary fuse element 256 opens, current will be directed to thechip fuse 254 and cause a dramatic increase in current and heatexperienced by the chip fuse 254. The increased current and/or increasedheat attributable to the current may be sensed by the smart card 252 anda signal may be sent to the communications device 114, which may be areader or reader terminal 258 connected to the card 252 to read datatherefrom.

Communication to the reader 258 could be established wirelessly with anantenna structure 260 or transponder device 262 in communication withthe smart card 252. Alternatively, a direct current path could beprovided from the smart cart 252 to the reader 258. More than one smartcard 252 may communicate with the reader 258, and each of the smartcards 252 associated with a circuit protector may include the same ordifferent modular programming scheme for data collection and response.As desired, the card 252 may include a contact interface whichphysically connects to the reader 258, or a contactless interface havingan antenna structure embedded in the card for remote access to the card252 without physical access.

Once the signal is received by the reader 258, the reader 258 transmitsor otherwise communicates signals and data to the overview and responsedispatch system 118 by any of the aforementioned methods. In turn, theoverview and response dispatch system 118 takes appropriate action tonotify personnel and instruct personnel regarding the location of areplacement fuse, pinpoint the identity of the operated fuse, and ordera replacement fuse.

4. Mechanical Monitor Systems

FIG. 11 is a schematic block diagram of another type of status elementand circuit protector monitoring assembly 268 that may be used in thecircuit protector management system 112 and the method 130.

As shown in FIG. 11, the assembly 268 includes a circuit protector 108and a panel 104. The circuit protector 108 is a fuse 270 that is similarto the fuse 162 shown and described in relation to FIG. 3, but includesa status element 110 in the form of a mechanical status element 272which is movable from a first position when the fuse 270 is operationalto a second position when the fuse 270 has operated to break thecircuit. In the illustrated embodiment, the status element 272 is aspring loaded pin movable from a first position generally flush with theend cap 274 when the fuse is operative to a second position (shown inphantom in FIG. 11) projecting from the end cap 274 when the primaryfuse element 276 opens to break the circuit through the fuse 270. Suchmechanical indicators and their equivalents are known and not describedin detail herein. When the pin 272 is moved to the second position(illustrated in phantom in FIG. 11) the pin 272 activates thecommunication device 114 to signal the overview and response dispatchsystem of an opened fuse.

Once the communications device 114 is activated, the communicationsdevice 114 transmits or otherwise communicates data to the overview andresponse dispatch system 118 by any of the aforementioned methods. Inturn, the communications device 114 signals the overview and responsedispatch system 118 of the operated fuse, and the overview and responsedispatch system takes appropriate action to notify personnel andinstruct personnel regarding the location of a replacement fuse, locatethe operated fuse, and order a replacement fuse.

Additional components, including but not limited to proximity sensorsand limit switches could be used in conjunction with the mechanical pin272 or another mechanical indication feature, including spring loadedelements and electromagnetic elements, to trigger signals to thecommunications device 114 to indicate opened fuses. Additionally,optical systems and scanners could be employed to detect relativemovement of the pin 272 or other mechanical feature of the fuse 270 asthe fuse operates. Using these or other additional components, multiplefuses 270 could be employed with a single communications device 114 byinputting the sensors and switches to the communications device 114.

5. Monitoring Module Systems

FIG. 12 is a perspective view of an exemplary circuit protector 108 andpanel 104 that may be used in the circuit protector management system112 and the method 130 wherein the status elements 110 are provided inthe form of a monitoring module assembly 300. The monitoring moduleassembly 300 is associated with a plurality of circuit protectors in theform of fuses 302, and the assembly includes a plurality of monitoringmodules 304 that are attached to the bodies 306 of the respective fuses302. In an exemplary embodiment, the monitoring modules 304 areindividually mounted to the fuse bodies 306 via a clip 308 to anexterior surface of the respective fuse bodies 306, thereby facilitatingretrofit installation to the fuses 302 in an electrical system. Aspreviously explained, the fuses 302 may be housed and arranged in thepanel 104 in the electrical system to interconnect power supplycircuitry 102 and various loads 106 in the electrical system.

The monitoring modules 304 may each include contact arms 310 extendingoutwardly form the modules 304 in a direction substantially parallel tothe respective fuse body 306. The contact arms 310 of the respectivemodules 304 mechanically and electrically engage the terminal elements312 of the fuses 302 so that the fuses 302 may be monitored in use. Aprimary fuse element 313 defines an interruptible current path betweenthe terminal elements 312 of each of the fuses 302, and when the currentpath is opened or interrupted in an overcurrent condition, the modules304 sense the operation of the fuses 302 in real time.

In an exemplary embodiment, the monitoring modules 304 include sensormodules 314 associated with some of the fuses 302 and a communicationsmodule 316 associated with one of the fuses 302. The sensor modules 314and the communications module 316 may be interconnected to one anothervia interface plugs 318 and three wire connections, for example, asillustrated in FIG. 12.

Referring now to FIG. 13, the construction of the sensor modules 314 andthe communications module 316 will be described. Each sensor module 314includes a sensor 330, an input/output element 332 connected to thesensor 330, and a signal port 334. The sensor 330 is connected to thecontact arms 310 that are connected to the terminal elements T₁ and T₂of one of the circuit protector fuses 302A. In one embodiment, thesensor 330 is a voltage sensing latch circuit having first and secondportions optically isolated from one another. When the primary fuseelement 313 of the fuse 302A opens to interrupt the current path throughthe fuse 302A, the sensor 330 detects the voltage drop across theterminal elements T₁ and T₂ of the fuse 302A. The voltage drop causesone of the circuit portions, for example, to latch high and provide aninput signal to the input/output element 332. Acceptable sensingtechnology for the sensor 330 is available from, for example, SymCom,Inc. of Rapid City, S. Dak.

While in the exemplary embodiment, the sensor 330 is a voltage sensor,it is understood that other types of sensing could be used inalternative embodiments to monitor and sense an operating state of thecircuit protector 302A, including but not limited to currenttemperatures and temperature sensors that could be used to determinewhether the primary fuse element 313 has been interrupted in anovercurrent condition to isolate a portion of the associated electricalsystem.

In a further embodiment, one or more additional sensors or transducers331 may be provided, internal or external to the sensor module 314, tocollect data of interest with respect to the electrical system and theload connected to the fuse 302A. For example, sensors or transducers 331may be adapted to monitor and sense vibration and displacementconditions, mechanical stress and strain conditions, acousticalemissions and noise conditions, thermal imagery and thermalographystates, electrical resistance, pressure conditions, and humidityconditions in the vicinity of the fuse 302 A and connected loads. Thesensors or transducers 331 may be coupled to the input/output device 332as signal inputs. Video imaging and surveillance devices 333 may also beprovided to supply video data and inputs to the input/output element332.

In an exemplary embodiment, the input/output element 332 may be amicrocontroller having a microprocessor or equivalent electronic packagethat receives the input signal from the sensor 330 when the fuse 302Ahas operated to interrupt the current path through the fuse 302A. Theinput/output element 332, in response to the input signal from thesensor, 330, generates a data packet in a predetermined message protocoland outputs the data packet to the signal port 334. The data packet maybe formatted in any desirable protocol, but in an exemplary embodimentincludes at least an identification code, a fault code, and a locationor address code in the data packet so that the operated fuse may bereadily identified and its status confirmed, together with its locationin the electrical system. Of course, the data packet could contain otherinformation and codes of interest, including but not limited to systemtest codes, data collection codes, security codes and the like that isdesirable or advantageous in the communications protocol.

Additionally, signal inputs from the sensor or transducer 331 may beinput the input/output element 332, and the input/output element 332 maygenerate a data packet in a predetermined message protocol and outputthe data packet to the signal port 334. The data packet may include, forexample, codes relating to vibration and displacement conditions,mechanical stress and strain conditions, acoustical emissions and noiseconditions, thermal imagery and thermalography states, electricalresistance, pressure conditions, and humidity conditions in the vicinityof the fuse 302 A and connected loads. Video and imaging data, suppliedby the imaging and surveillance devices 333 may also be provided in thedata packet.

The communications module 316 in an exemplary embodiment may alsoinclude a sensor 330, an input/output element 332, and a signal port334. Like the sensor module 314, the sensor 330 of the communicationsmodule 316 is connected to the contact arms 310 that are connected tothe terminal elements T₁ and T₂ of one of the circuit protector fuse302B, and the sensor 330 of the communications module 316 operatessubstantially in the same manner as described above to sense anoperating state of a primary fuse element 313 in the fuse 302B. However,when the sensor 330 detects operation of the fuse 302B, the input/outputelement 332 generates and outputs a corresponding data packet to atransmitter 340 that communicates with the overview and responsedispatch system 118. The transmitted data packet from the communicationsmodule 316, in addition to the data packet codes described above, alsoincludes a unique transmitter identifier code so that the overview andresponse dispatch system may identify the particular communicationsmodule 316 that is sending a data packet.

In one embodiment, the transmitter 340 is a low power radio frequency(RF) signal transmitter that digitally transmits the data packet in awireless manner. Point-to-point wiring in the electrical system for fusemonitoring systems is therefore avoided, although it is understood thatpoint-to-point wiring could be utilized in some embodiments of theinvention. Additionally, while a low power digital radio frequencytransmitter has been specifically described, it is understood that anyof the aforementioned wireless communication schemes and equivalentscould alternatively be used if desired.

The communications module 316 further includes an on-board battery powersupply 342 that powers the electronic sensor 330 and/or the input/outputelement 332 and the transmitter 340 of the communications module 316.The battery 342 may also supply power, through the interface plugs 318,to the input/output element 332 and/or the sensor 330 of thecommunications module 316. Thus, multiple sensor modules 314 may bepowered by a single communications module 316 to monitor a plurality offuses 302. For example, one of the three wire connections shown in FIG.12 may be a power line connecting the battery 342 to one or more sensormodules 314. The battery 342 may be replaceable as needed to extend thelife of the monitoring assembly 300, and a test button, for example, maybe provided in the communications module 316 to ensure that the battery342 is powered and the module electronics in the communications module316 and connected sensor modules 314 are working properly. Reset buttonsmay also be provided in the modules for testing and diagnostic purposes.A power harvesting device 343, such as rechargeable batteries and thelike that store energy when not in use may be utilized in addition to orin lieu of the battery 342. A backup power supply 345, or other circuitsof the electrical system may also be used to power the sensor andcommunications modules 314, 316. Energy storage components such ascapacitors may also be employed, and switching devices may be providedto switch between energy storage elements, power harvesting devices,batteries, and backup power supplies, or other circuitry to powercommunications after circuit protector 302A has operated.

Also, the signal port 334 of the sensor module 314 may communicate, viathe interface plug 318 with the signal port 334 of the communicationsmodule 316. Thus, for example, considering the embodiment of FIG. 13,when the primary fuse element 313 opens in the fuse 302A associated withthe sensor module 314, the sensor module input/output element 332generates a data packet that is sent to the sensor module signal port334 through the interface plug 318 and to the communications moduleinput/output element 332 for transmission via the transmitter 340. Thus,signals are simply passed through the respective signal ports 334 viathe interface plug 318, and multiple sensor modules 314 may be connectedto a single communications module 316 via interconnecting the interfaceplugs 318 to the signal ports 334. In such a manner, the number ofcommunication modules 316 and transmitters 340 in the circuit protectormanagement system may be reduced, together with associated costs andmaintenance issues.

Additionally, status indicators and the like such as light emittingdiodes (LED's) may be provide in the sensor and communication modules314, 316 to locally indicate an operated fuse 302. Thus, whenmaintenance personnel arrives at the location of the operated fuse 302,the status indicators may provide local state identification of thefuses associated with the modules 314, 316.

Notably, the monitoring modules 304, including the sensor modules 314and communications modules 316 are provided in modular form whereindifferent sized mounting clips 308 and differently dimensioned contactarms 310 may be provided to accommodate fuses of varying sizes andconfigurations. By providing various mounting clips and mountingstructure, together with various contact arms and contact structure toestablish electrical contact with the fuses, the modules 304 are readilyadaptable to accommodate most if, not all, types of fuses, and themodules 304 may be retrofitted to complex electrical systems withsnap-on engagement, thereby minimizing installation time and complexityin existing electrical systems.

FIGS. 14 to 21 illustrate the adaptability of monitoring modules 304 tovarious types of circuit protectors and systems.

FIG. 14, for example, illustrates a single phase monitoring assembly 350including a monitoring module 304 and a circuit protector in the form ofa fuse 352. The module 304 includes a body or housing 354, a sensorboard 356, a communications board 358, and a battery 360 mounted thereinand forming a protective enclosure thereabout. The sensor board 356includes, for example, sensing circuitry 330 to detect operation of thefuse, such as the aforementioned voltage sensing, current sensing, ortemperature sensing circuitry, and the communications board includes,for example, the input/output element 332 and the transmitter 340 forgenerating data messages and signals when the fuse 352 operates to openthe circuit.

The signal port 334 is exposed through an outer surface 362 of themodule 304, and in an exemplary embodiment, the signal port 334 includescontacts 364 that interface with, for example, mating interconnect plugssuch as the plugs 318. The module 304 may therefore be connected toanother monitoring module 304 in the larger electrical system.

With the communications board 358 and battery 360, the module 304 mayfunction as the communications module 316 described above. Without thecommunications board 358 and battery 360, the module 304 may function asa sensor module 314 as described above. The communications board 358 mayinclude a low power radio frequency transmitter as described above, ormay alternatively communicate with a remote device by any of theaforementioned methods.

A test/reset button 366 extends through the outer surface 362 of thehousing 354, and a status indicator opening 368 is provided in the outersurface 362. A light emitting diode (LED), for example, may be connectedto the sensor board 356 and may be illuminated when the fuse 352 opensto isolate a portion of electrical circuitry connected thereto, therebyproviding visible local indication in the housing 354. Contact arms 370are attached to the housing 354 and are electrically connected to thesensor board 356 for monitoring of the fuse 352 when the contact arms370 are mechanically engaged to the terminal elements of the fuse 352.

A mounting element 372 attaches to the exterior surface of the fusebody, thereby permitting retrofit installation to the fuse 352 when thefuse 352 is installed in an electrical system.

FIG. 15 is a side elevational view of the monitoring assembly 304illustrating the contact arms 370 depending from the housing 354 towardthe fuse 352, and resilient contact elements or extensions 380 engagingthe respective terminal elements 382 of the fuse 352. The contact arms370 may extend inwardly and toward one another to accommodate arelatively small fuse 352 in relation to the module 304.

As the mounting element 372 is installed in the direction of arrow A, itsnaps over the exterior surface of the fuse body 384 and resilientlysecures the module 304 to the fuse 352. The contact elements 380 arecompressed or deflected as they engage the fuse terminal elements 382when the module 304 is installed, and the deflection or compression ofthe terminal elements 382 provides a normal contact force or bias forceagainst the fuse terminal elements 682 in the direction of arrow A.Mechanical and electrical engagement of the module 304 and the fuseterminal elements 382 is therefore ensured. The contact elements 380 areelectrically connected to the sensor board 356 for monitoring of theoperation state of the fuse 352.

A removable battery door 386 may be mounted to one side of the housing354 and may be removable, for example, in the direction of arrow B toprovide access to the battery 360 for inspection and replacement withinthe module 304. The signal port 334 extends from and is exposed throughthe outer surface 362 of the module housing 354 that, in use, may definea front face of the module 304. Locating the signal port 334 in a frontface of the module 304 that opposes the fuse 352 provides unobstructedaccess to the signal port 334 for ease of interconnection to othermodules via interface plugs 318 as described above.

FIG. 16 is a bottom exploded view of a circuit protector monitoringassembly kit 400 that may be used to configure modules the modules 304for varying types of circuit protectors. The kit 400 may be assembledinto a monitoring module 304 that may be a sensor module 314 or amonitoring module 316.

The kit 400 includes a housing 402 that may formed into a generallyrectangular shape including a top surface 404, a bottom surface 406,opposing side walls 408 and 410, and opposing end walls 412, 414 forminga box-like structure that houses, for example, the above describedsensing circuitry, communications transmitter, and battery power supply.The housing 402 may be assembled with a snap-fit engagement withouttools in one embodiment. While a generally rectangular shape isillustrated in an exemplary embodiment, it is recognized that othershapes and configurations of housings could be used in alternativeembodiments.

The bottom surface 406 may include mounting shoulders 415, a retainingflange 416, and contact arm receptacles 418. A mounting element 420 isattachable to the retaining flange 416, and contact arms 422 areattachable to the contact receptacles 418.

The mounting element 420, in one embodiment, may include a U-shaped base424, and resilient arms 426 extending from the base 424 and having acurvature selected to inter-fit with an outer surface of a fuse body.Outwardly tapered edges 428 are provided on distal ends of the arms 426to separate the arms 426 away from one another in the direction ofarrows C and D as the mounting element 420 is installed over an exteriorsurface of the fuse with, for example, clip-on or snap-fit engagement. Aretaining aperture is formed in the base 424, and when the base 424 isinserted over the housing retaining flange 416 and positioned betweenthe housing mounting shoulders 415, the retaining aperture is alignedwith the retaining flange 416. By pressing the base 424 against thehousing 402, the retaining flange 416 may be resiliently deflected andforced through the retaining aperture in the base 424. When the flange416 returns to its original position, the flange 416 locks the base 424to the bottom surface 406 of the housing 402, also with a snap-on orclip-on engagement.

In an exemplary embodiment, the contact arms 422 each include aconnecting portion 430, an extension portion 432 and a shroud 434. Aresilient contact element 436, such as a conductive wire element orequivalent, extends through the extension and connecting portions 430,432 and is bent or curved beneath the shroud 434 of each extension. Theconnecting and extension portions 430, 432 may be formed of anonconductive or insulative material, such as plastic, to preventinadvertent contact with the elements 436 in use when the kit 400 isinstalled to an energized circuit protector. The connecting portions 430and one end of the contact elements 436 may be inserted into thereceptacles 418 in the housing bottom surface 406 and retained theretowith a snap-fit or clip-on engagement. The contact elements 436 areelectrically connected to the sensor board, directly or indirectly, whenthe connecting portions 430 are received in the receptacles 418.

The kit 400 may therefore be assembled quickly by hand and without toolsdue to the snap-fit connections of the component parts, therebyproviding a convenient and low cost monitoring assembly for circuitprotectors. By providing various sizes, shapes and configurations ofmounting elements 420 and various sizes, shapes and configurations ofcontact arms 422, the kit 400 may be assembled into various differentconfigurations to accommodate different types of fuses.

For example, FIG. 17 illustrates one exemplary version of the kit 400attached to a knife blade fuse 450. A mounting element 420A is providedto engage an exterior surface of the fuse body 452, and elongatedcontact arms 422A are provided to mechanically end electrically connectto the knife blades 454 of the fuse 450. The contact arms 422A areextended outwardly and away from the nodule housing 402 to reach theknife blades 454 at a distance from the module housing 402.

FIG. 18 illustrates another exemplary version of the kit 400 attached toa fuse 460 having a greater diameter than the fuse 450 shown in FIG. 17,but having a reduced axial length compared to the fuse 450. A differentmounting element 420B, dimensioned to inter-fit with the fuse body 462of the fuse 460 is therefore employed with the housing 402, anddifferent contact arms 422B are provided to mechanically andelectrically connect to the terminal elements 464 of the fuse 460.

Thus, as demonstrated in FIGS. 14-18, by mixing and matching mountingelements 420 with contact arms 464 and attaching them to a universallyusable housing 402, whether for a sensor module or a communicationsmodule, the kit 400 may easily assembled into many differentconfigurations to engage and monitor fuses of many sizes and shapes.Once the kit 400 is assembled and installed to a fuse, the kit 400 maybe interconnected via the signal ports 334 in the top surface 404 of thehousing 402 in the manner described above.

FIGS. 19 and 20 illustrate another embodiment of a circuit protectormonitoring assembly 500 that may be used in the circuit protectormanagement system 112 shown in FIG. 1 and the method 130 shown in FIG.2. The assembly 500 includes a monitoring module 502 that is a threephase device interfacing with circuit protector fuses 504 eachcorresponding to one phase of a three phase electrical power system.

The module 502 may include a protective housing 506, a plurality ofsensor boards 508 in the housing 506, and a communications board 510powered by an on-board power supply battery 512. As with the foregoingembodiments, the sensor boards 508 may include voltage sensingcircuitry, current sensing circuitry, or temperature sensing circuitryto monitor each of the fuses 504, and the communications board 510 mayinclude a low power radio frequency transmitter, or may communicate byother methods as described above. The sensor boards 508 areinterconnected with one another and the radio communications board 510so that, when any of the fuses 504 opens to interrupt one phase ofcurrent through the fuses 504, a signal is generated and sent to thecommunications board 510 for transmission to remote device, such as theoverview and response dispatch system 118.

A test/reset button 514 may be provided on the communications board 510,and the sensor boards 508 may include LEDs or other local stateindicators as desired to indicate the operating state of the fuses 504associated with the three phases of electrical power.

The assembly 500 includes center contact arms 520 engaging the terminalelements 522 of one of the fuses 504, and side contact arms 524 engagingthe terminal elements 522 of the other fuses 504. The side contact arms524 may include a plurality of mounting apertures therein, and contactshrouds 526 are selectively postionable in the mounting apertures of theside contact arms 524 via locating pins 527. Thus, the position of thecontact shrouds 526 on the contact arms 524 relative to the centercontact arm 520 is adjustable in a direction of arrow E so that theassembly 500 may be used with fuses of greater or lesser diameter thanthe fuses 504, and having a greater or lesser spatial separation betweencenterlines of the fuses when installed in an electrical system.

A single mounting element 530 engages one of the fuses 504, with thecontact arms 524 extending outward and away from the housing 506 tomechanically and electrically engage terminal elements 532 of the fuses504 so that the sensor circuitry in the module 502 may monitor theoperating state of the fuses 504. In an alternative embodiment, themounting element 530 may engage more than one of the fuses to secure theassembly 500 to the fuses.

A removable battery door 528 may be provided on one side of the module502 for access to the battery 512. The module 502 may be supplied in akit form similar to the kit 400 described above with varying mountingelements 530 and contact arms 524 that may be assembled into differentconfigurations for monitoring various types of fuses in three phasecurrent applications.

FIGS. 21 and 22 illustrate another embodiment of a circuit protectormonitoring assembly 540 that may be used in the circuit protectormanagement system 112 shown in FIG. 1 and the method 130 shown in FIG.2. The assembly 540 includes the monitoring module 502, and a removablebattery cover or door 542 providing access to the battery 512.

Unlike the assembly 500, the assembly 540 includes center contact arms544 engaging the terminal elements of one of the fuses 546, and sidecontact arms 548 engaging the terminal elements the other fuses 546. Theside contact arms 548 are pivotal or rotatable with respect to themodule housing 506 in the direction of arrows F and G to adjust aseparation of the contact arms 544, 548 relative to the module housing506 and accommodate fuses of various diameters or outer dimension in athree phase application.

The assembly 540 may be provided in kit form having contact arms 544,548 of varying lengths to mechanically and electrically engage terminalelements of a variety of sizes of fuses, and may be provided withvarious mounting elements 530 to engage the modules 502 to differentfuse bodies.

Having described some exemplary embodiments of three phase monitoringmodules and single phase monitoring modules, it is recognized that thethree phase modules and single phase modules may be used in combinationin a complex electrical system wherein circuit protectors are employedto isolate single phase and three phase electrical loads and powersupplies from one another. The modular construction and assembly of themonitoring modules, mounting elements and contact arms permits wideapplication of the monitoring modules to existing electrical systemshaving fuses of various sizes, shapes and configurations. When used in acircuit protector management system 112 such as that described above tocommunicate signals to the overview and response dispatch system 118,the monitoring modules and monitoring assemblies provide an effectivemonitoring status and detection scheme for an electrical system having avariety of different types of circuit protectors.

A versatile, relatively low cost, expandable and adaptable circuitprotector monitoring system is therefore provided that may beretrofitted to existing electrical systems without modifying theelectrical system and infrastructure. It is understood, however, that infuture equipment, or perhaps for smaller electrical systems, themonitoring, communications, and management components could be built-into the electrical system and circuit protector products themselves.

6. Monitoring Assembly and System Combinations

The monitoring assemblies described above may be mixed and matched inthe electrical system 100 as desired or as needed for a particularapplication. Thus, for example, circuit protectors in the electricalsystem that protect critical loads in the system may include moreadvanced status elements that operate as data collectors, while othercircuit protectors in the system may be monitored with more basic, andlower cost status elements. Likewise, data collection may be requiredfor some circuit protectors but not for others, and some of theelectrical system may be retrofitted with monitoring modules while otherparts of the system may include monitoring technology integrated intothe system hardware and infrastructure.

Additionally, it is contemplated that the status elements of theabove-described assemblies could be mixed and matched in differentassemblies. For example, reader or interrogator elements could beemployed in modular monitoring assemblies and engaged to circuitprotectors with snap-on retrofit installation. As another example, smartcard technology or mechanically actuated status elements could beincorporated into module monitoring assemblies.

Any of the foregoing embodiments of circuit protectors and statuselements may be combined with other known fuse state indication featuresfor user convenience. For example, the fuses may include combustiblefuse state indicators, temperature responsive materials, and other knownmaterials which visually indicate the state of the fuse as opened orunopened. Thus, by denoting a color change or other physicaltransformation in the appearance of a portion of the fuse, maintenancepersonnel may more easily identify operated fuses in an area identifiedby the overview and response dispatch system 118. In other words, visualfuse state identification features may provide confirmation of the fusestate identified by the overview and response dispatch system 118 whenmaintenance personnel arrive at the designated location.

Still further, while the foregoing embodiments of panels 104 and circuitprotectors 108 are described in the context of fuses, similartechnologies and methodologies could be employed with other types ofcircuit protectors such as, for example, circuit breakers and switchesto detect operation of the devices to more efficiently locate and resettripped breakers and opened switch paths, as well as to facilitatemonitoring, diagnostics and troubleshooting of the electrical system.

D. The Signal Transmission System

FIG. 23 schematically illustrates an exemplary signal transmissionsystem 580 for use with the circuit protector management system 112shown in FIG. 1 and the method 130 shown in FIG. 2. A plurality ofcircuit protector panels 104 are distributed throughout the electricalsystem, and each circuit protector panel 104 in the electrical systemthat is to be monitored includes, for example, a monitoring assemblysuch as those described above for transmitting data signalscorresponding to the operational state one or more circuit protectors,such as fuses, in the blocks 106. In the manner described above, thecommunications module 316 generates a wireless data signal or datapacket when one of the fuses associated with the monitoring assembliesopens. In an exemplary application, the monitoring assemblies includethe communications modules 316 describe above.

The wireless data signals from the communications modules 316 may bereceived, for example, by one or more repeater/router elements 582located within the transmission range of the communications moduletransmitter 340. In an exemplary embodiment, the repeater/routerelements 582 may be wireless, radio frequency transmission devices orequivalent devices that receive, for example, a digitally transmitted RFdata signal from the communications module 316 and forwards the datasignal to a signal collection and conditioning device, referred toherein as a gateway device 584. The gateway device is, in turn, incommunication with the overview and response dispatch system 118.Alternatively, the repeater/router elements 582 may be anotherelectronic device that functions to feed transmitted data from thecommunications module 316 to the gateway device 584. For example, USB,serial port connections or other connection means and their equivalentsmay be utilized to interconnect the repeater/router elements 582 and thegateway device 584.

In an exemplary embodiment, a plurality of repeater/router elements 582are provided around and about the various panels 104, and therepeater/router elements 582 form a mesh network defining multiplesignal paths to forward signal transmissions from the communicationmodules to a single gateway device 584 in communication with theoverview and response dispatch system 118. Repeater/router elements 582and mesh network configurations are commercially available from, forexample, RF Monolithics, Inc. of Dallas, Tex. Many different meshtopologies are known and may be employed, including but not limited tostar configurations, ring configurations, cloud configurations, linearconfigurations and the like. The mesh network may be algorithmicallybased and configured to meet specific needs for specific installations.

The network of repeater/router elements 582 in one embodiment isself-configuring and self healing with autorouting and reroutingcapability as the network changes, and is highly scalable whereinthousands of circuit protectors may be monitored in the circuitprotector management system 112. Considering that the various panels orblocks 106 may be located in different locations, and even in differentbuildings, the management system 112 is versatile adaptable to existingelectrical systems 100, and is accommodating to addition or subtractionof additional electrical loads and circuit protectors in the electricalsystem.

While a plurality of repeater/router elements 582 are illustrated inFIG. 23, it is understood that as few as one repeater/router element 582could be provided in an alternative embodiment. Likewise, more than onegateway device 584 could be employed if desired.

The gateway device 584 may be a network based computer server system, apersonal computer, a computer workstation, a programmable logiccontroller or other electronic controller, a processor-based hand helddevice or another electronic device or equivalent thereof that mayreceive, condition, process or interpret signals from repeater/routerelements 582, and communicate the signals to the overview and responsedispatch system 118 as explained further below.

FIG. 24 schematically illustrates the signal transmission system 580providing data communication between the repeater/router elements 582and the overview and response dispatch system 118 via the gateway device584.

As shown in FIG. 24, the gateway device 584 may be an embedded computerdevice including a receiver 588 for receiving, for example, wirelessdata transmission from the repeater/router elements 582 when one or moreof the status elements, such as the monitoring modules 304 describedabove or any of the status elements described in relation to FIGS. 3-11signals the repeater/router elements 582 of an operated circuitprotector that has isolated portions of electrical circuitry in anelectrical system. The receiver 588 may be a part of the gateway device584 or may be separately provided and interfaced with the gateway device584 to receive incoming signal transmissions from the repeater/routerelements 582.

Data packets may be transmitted repeatedly from the circuit protectormonitoring assemblies and/or the repeater/router elements 582 withinspecified time periods to ensure that the data packets are completelyreceived, processed, and optionally acknowledged by a gateway device 584and/or the overview and response dispatch system 118. Repeatedtransmission of data signals avoids collision of signals when more thanone of the circuit protectors operates at approximately the same time.Also, the repeater/router elements 582 may add a routing code, a timestamp or other information to the data packet so that the overview andresponse dispatch system 118 may monitor the communication system andsignal path between the monitoring modules and the overview and responsedispatch system 118.

As shown in FIG. 24, the gateway device 584 includes gateway applicationsoftware 590 for processing incoming data signals through therepeater/router elements 582. The gateway application software may beimplemented on, for example a Linux, UNIX or Windows-based operatingsystem and equivalents thereof as those in the art will appreciate.

The application software 590 may include, for example, configuration andmonitoring algorithms 592 and interactive graphic user displays forassisting the monitoring assembly installers and system or sitetechnicians 594 with setting up, testing and troubleshooting thecommunications between the status elements, the repeater/router elements582 and the gateway device 584. The installers or technicians 594 may belogged on to the gateway device 584 at a remote location from thegateway device through, for example, a web server 596 connected to thegateway device 584, or installers or technicians may work directly witha local user interface associated with the gateway device 584 itself.More than one installer or technician could log on to the gateway device584 for access to the application software 590 to supply and receivenecessary information to install, maintain, or modify the configurationof the monitoring components and the signal transmission componentsassociated with circuit protectors.

Using the configuration and monitoring algorithms 592 and interactivegraphic user displays, status elements and repeater/router elements maybe deemed, considered, determined or identified by the system accordingto an operating mode thereof. For example, applicable monitoring modesfor the status elements may include a “registered” status wherein thestatus elements are authorized and compatible with the gateway device; a“discovered” status wherein the status element is installed but notactivated to communicate with the management system; an “activated”status wherein the status elements are associated with a specificcircuit protector and communicating with the management system; a“suspended” status wherein the status element has been caused not tofunction; a “deactivated” status wherein the element is uninstalled andnot associated with any circuit protector; or an “offline” statuswherein the status element is activated but not reporting to themanagement system 112. The signal transmission components, including butnot limited to the repeater/router elements 582, may likewise bedesignated and identified by the management system.

Additional characterization, grouping, or labels of the status elementsfor the circuit protectors may be provided for informational purposes toprovide an overview of the entire management system and status of themonitoring and signal transmission components as the system is expanded,contracted, or changed in use, and as more electrical loads orconfiguration of the electrical system are changed or adapted over time.The operating modes may be automatically detected by the gateway device584, or may be manually entered by installers, technicians, and servicepersonnel for the status elements. The gateway device 584 may thereforeintelligently manage the addition or subtraction of circuit protectorstatus elements and repeater/router elements 582 to and from the circuitprotector management system 112.

Timestamp alert algorithms 598 and associated displays may also beincluded in the application software 590 for inspection and maintenancepurposes wherein the communications systems between the status elements,the repeater/router elements 582 and the gateway device 584 areperiodically verified to ensure operation of the monitoring andcommunication components in the circuit protector management system 112.As one example, the circuit protector status elements and/or therepeater/router elements 582 may be programmed to communicate or reportwith the gateway device 584 on a periodic basis or interval, sometimesreferred to as a watchdog interval, and the gateway device 584, throughthe application software 590, could monitor the operating status orhealth of the management system by comparing signals received from thestatus elements and the repeater/router elements with informationentered into the system, via the configuration and monitoring algorithmsand displays 592, of the status elements and repeater/router elementsknown to be in the circuit protector management system 112. If, forexample, one of the repeater/router elements 582 or one of the circuitprotector status elements does not report in a predetermined time frame,an error flag may be set and alert may be generated to theinstaller/site technician 594, either directly from the gateway device584 or indirectly through the overview and response dispatch system 118.The timestamp alert algorithms 598 and the configuration and monitoringalgorithms 592 may then be accessed by site technicians 594 to diagnoseand troubleshoot the circuit protector management system 112.

Data reduction algorithms 600 may be included in the applicationsoftware 590 for processing signal transmissions from therepeater/router elements 582 before communicating with the overview andresponse dispatch system 118. For example, the gateway device 584 mayfilter incoming data signals and identify duplicate signal transmissionsthat may occur, for example, when more than one of the repeater/routerelements 582 transmits the same signal to the gateway device, or asanother example, when the same status element signals therepeater/router elements 582 more than once to avoid for example,collision of data signals. Duplicate signals may be discarded or deletedby the gateway device 584 prior to communicating signals to the overviewand response dispatch system 118.

The data reduction algorithms 600 may also reduce or eliminateinformation from the data signals that are not necessary for theoverview and response dispatch system 118 functionality. For example,messaging protocol information pertinent to the radio frequencytransmission of the data signals but not pertinent to the networkmessaging protocol for communication with the overview and responsedispatch system 118, may be stripped, eliminated, or deleted from thedata signals before transmission to the overview and response dispatchsystem 118.

Data logging algorithms 602 and associated displays may also be includedin the gateway application software 590 for supplying and receivinginformation and data and generating reports of management systemactivity. Such information and reports, as explained above, could be auseful tool for proactive management of an electrical system to identifyissues in the electrical system that may cause operation of one or morecircuit protectors to isolate portions of the circuitry, and perhapsallow for technicians 594 to take steps to control and manage theelectrical system in a way that opening of the circuit protectors isavoided altogether, which is especially advantageous in criticalapplications, such an electrical system for a hospital.

The data logging algorithms 602 and displays could also be used toinitiate special procedures responsive to real time operation of theelectrical system, such as shutting down certain machines or portions ofthe circuitry at high risk when one or more of the circuit protectorsoperates. Such procedures may be particularly appropriate, for example,when one phase of a three phase electrical power supply becomes isolatedor interrupted due to an operated circuit protector, and a machine orload is temporarily powered by only two phases of electrical current.

Each of the configuration and monitoring algorithms 592, the timestampalert algorithms 598, the data reduction algorithms 600 and the datalogging algorithms 602 are interconnected with a database 604 or memorystorage medium needed to store inputted, collected, and received data,operating parameters and settings, and the machine readable operatingsoftware codes and algorithms, etc. that the gateway device 584 mayrequire.

A communications interface 606, a communications driver 608, andinterface drivers 610 may also be provided in the gateway applicationsoftware 590 to provide communication between operative components inthe circuit protector management system 112.

The gateway device 584 may also perform authentication, verification, orsecurity algorithms to ensure the integrity of the management systemcommunications, as well as perform diagnostic, testing, andtroubleshooting procedures to ensure proper installation and operationof the circuit protector status elements and repeater/router elements582 in the overall circuit protector management system 112.

In an exemplary embodiment, a portal monitoring and communicationsapplication 612 may be provided for further processing of data signalsto convey information to the overview and response dispatch system 118.The communications application 612 may include protocol algorithms 614to convert message data from the incoming radio frequency datatransmission protocol, for example, to a preferred network messagingprotocol, including but not limited to HTTPS, SOAP, and XML protocolsand their equivalents known in the art, and internet protocol algorithms616 for transmitting the network messaging protocol data packets to theremote overview and response dispatch system 118 via, for example, anEthernet connection 618.

In an exemplary embodiment, the incoming radio frequency data protocolis a byte oriented protocol having multiple bits representative ofinformation of interest. For example, the status elements may transmitdigital data signals including bits corresponding to a unique radioidentifier, a manufacturer serial number for the status element, adevice type code for the circuit protector, a location or address codefor the circuit protector, a power/control code, an equipmentidentification code, and state parameter codes such as testing codes,faults codes, and codes pertaining to operating conditions of thecircuit protector and/or circuitry associated with the status elements.The data signals may also include codes relating to the ambientenvironment of the circuit protector or the associated electrical systemand loads, such as temperature codes, vibration codes, displacementcodes, mechanical stress codes, mechanical strain codes, acousticalemission codes, noise codes, thermal imagery codes, electricalresistance codes, pressure codes, humidity codes and video surveillancecodes.

The repeater/router elements 582 may add bits to the signal protocolcorresponding to a serial number of the respective repeater/routerelement, a device type code for the repeater/router, a wireless addressfor the repeater/router, a data packet sequence number, a location codefor the repeater/router, and state parameters pertaining to operatingconditions of the repeater/router elements.

The gateway device 584 converts the radio frequency transmissionprotocol to a second, and different messaging protocol for transmissionto the overview and response dispatch system 118. The second messageprotocol may also be byte oriented and include bits corresponding to theunique radio identifier, a serial number of an operated circuitprotector, a device type code for the operated circuit protector, alocation code for the operated circuit protector, a wireless address, anIP address for the gateway device, a time/date stamp, a softwarerevision code for the gateway application software and/or thecommunications application loaded on the gateway device, a hardwarerevision code for the gateway device, a packet count, an error count,and a predetermined number of error codes. When received by the overviewand response dispatch system 118, the gateway data message can be usedto quickly determine operation of the circuit protectors, locateoperated circuit protectors in the electrical system, and notify andsummon responsible personnel and technicians for quickly re-energizingdowned circuitry. Furthermore, all of the codes and data relating tosignal events in the system are logged for future use, retrieval, studyand analysis to evaluate the performance of the overall circuitprotector management system 112.

While some exemplary message codes have been described, it is understoodthat other types of codes, information and data representative ofcircuit protector products and operating status may be included inalternative embodiments, and it is also recognized that less than all ofthe exemplary protocol bits and codes could be used in other embodimentsof the signal transmission system 580. Implementation of the messageprotocols may be conventionally provided and is not specificallydescribed in further detail herein.

The gateway application software 590 and the communications application612 may run on a known operating system 620 loaded on the gateway device584, including but not limited to Windows, PocketPC, and Linux operatingsystems and their equivalents known in the industry. Having nowdescribed the various operating algorithms functionally, programming ofthe modules to operate in the manner described may be conventionallyprovided by those in the programming arts without further explanation.

In an exemplary installation, the gateway device 584 may be located atthe electrical system site, and the overview and response dispatchsystem 118 may be located remotely, although the overview and responsedispatch system 118 could be located at the site of the electricalsystem as well.

FIG. 25 is a flowchart of a method 630 executable by the gateway device584 in an exemplary embodiment. The gateway device 584 awaits signalsfrom the repeater/router elements, and receives the signals 632 in anymanner described above. Data reduction is performed 634 on the incomingsignals in the manner described above, and the incoming message protocolis converted 636 to a second message protocol, different from theincoming message protocol. Once the message protocol is converted 636,the gateway device communicates 638 the converted data message to theremote overview and response dispatch system 118 for action or attentionin the manner described above.

As appropriate or as needed, the gateway device runs 640 theconfiguration and monitoring algorithms and runs 642 the timestampalgorithms as described above. If an error is detected 644, the gatewaydevice may notify 646 a technician and perform data reduction procedures634 to prepare to send an error signal to the overview and responsedispatch system. If an error is not detected 644 during the time stampalgorithms and procedures, the gateway devices reverts to a dwell stateuntil another message is received 632 from the repeater/router elements.

Optionally, incoming messages may be authenticated 648 or otherverification and security algorithms and procedures may be implementedto ensure the integrity of the system communications. Data loggingprocedures are run 650 as needed during operation of the gateway device584, and data may be accessible by or be communicated to the remoteoverview and response dispatch system as desired.

FIG. 26 schematically illustrates the signal transmission system 580connected to an electrical system 100 and the management system 112. Theelectrical system 100 includes a power supply or power supply circuitry102 connected to multiple circuit protectors such as fuses 302 in acircuit protector panel 104. Each of the fuses 302 is associated with asensor module 314 or a communications module 316, and each of the fuses302 is connected to an electrical load 108. The interface plugs 318interconnect the sensor modules 314 to one another and to thecommunications module 316 in the manner described above. Due to theinterconnection of the modules 314, 316, when any of the fuses 302operates to isolate any of the loads 106, a data packet is presented tothe transmitter 340 of the communications module 316, and a wirelesssignal 660 is transmitted by the communications module 316. The wirelesssignal 660 is received and forwarded by at least one of therepeater/router elements 582 to the gateway device 584. The gatewaydevice 584, protected by a firewall 586, then communicates theinformation to the overview and response dispatch system 118.

The management system 112 includes the overview and response dispatchsystem 118, a user interface or display 662 connected to the overviewand response dispatch system 118, and may be in communication with theinventory management system 120 for automatic ordering of replacementfuses. A memory or database 664 may also be provided to log systemactivity and store needed information for the overview and responsedispatch system. For example, the database 664 may be used to decodeincoming data packet transmissions from the gateway device 584, and theuser interface 662 may be used to present information to responsiblepersonnel in tabular and graphic form with menu-driven displaysdescribed below. The database 664 may also be used for storage andretrieval of contact information for locating and summoning maintenancepersonnel.

FIG. 27 is an exemplary site diagram of an electrical facility 680housing an electrical system having many circuit protectors 302 to bemonitored in various panels 104 in the facility 680. Monitoring modules304, some of which are communication modules 316 and some of which aresensor modules 314 are associated with circuit protectors such as fuses302 scattered throughout the facility 680. A number of repeater/routerelements 582 are also strategically located in different locations inthe facility 680 within the operating range of the monitoring modules304, and specifically the communications modules 316. Therepeater/router elements 582, in turn, are in communication with acentralized gateway device 584 that communicates with the overview andresponse dispatch system 118 at a remote location via, for example, theInternet.

As FIG. 27 demonstrates, the management system can efficiently monitor alarge number of fuses 302, and as the size and complexity of thefacility 680 increases, the system is readily adaptable by addingadditional monitoring modules 304 and repeater/router elements 582. Theoverview and response dispatch system 118 directly interacts withfacilities management to provide real time system performance data andimmediate information so that downed circuitry may be re-energized asquickly as possible.

FIG. 28 further illustrates additional features of the management systemshown in FIGS. 26 and 27 in one implementation thereof. The fusemonitoring modules 304 are interfaced with a network 690 ofrepeater/router elements 582 that are, in turn, interfaced with thegateway device 584. The gateway device 584 may be connected to localnetwork interfaces and process monitoring interfaces of, for example,the facility 680. The portal communications application 612 of thegateway device 584, implemented in software or machine readable code,processes incoming signals from the repeater/router network 690. Afterprocessing by the portal communications application 612, the gatewaydevice 584 communicates with the Internet via an Ethernet connection 618and ultimately with the overview and response dispatch system 118. Inresponse to communications from the gateway device 584, the overview andresponse dispatch system 118 communicates with responsible personnel forthe electrical system through the Internet and communication towers 692,for example. to contact designated personnel by phone 694, pager 696,facsimile 698, email 700, or via a customer web site to providedirection and information regarding operated circuit protectors andre-energizing circuitry.

FIG. 29 schematically illustrates a further embodiment of anothercircuit protector management system wherein multiple status elements,such as the monitoring modules 304 or any of the status elementsdescribed above, communicate with repeater/router elements 582 andmultiple gateway devices 584 in different locations or facilities 710and 712. The gateway devices 584 in each facility 710, 712 communicatewith the overview and response dispatch system 118 that may be, forexample, at a third location remote from both of the facilities 710 and712. In such a manner, and when the gateway data message includes acustomer identifier, the overview and response dispatch system 118 maydistinguish messages regarding the operation of the electrical systemcorresponding to the facility 710 from messages regarding the operationof the electrical system corresponding to the facility 712. Thus, whenthe facilities 710 and 712 are owned by different customers A and B asshown in FIG. 29, the overview and response dispatch system 118 mayadvise and alert multiple customers of the real time operation of theirelectrical systems, and provide each customer with specific informationto efficiently re-energize electrical circuitry when the circuitprotectors operate to protect the electrical systems.

In an exemplary embodiment, the overview and response dispatch system118 may be located at the site of a circuit protector manufacturer,thereby providing real time information to the operation and performanceof its fuse protection products in the field. The manufacturer mayaccess the information input to or collected by the overview andresponse dispatch system 118 to provide superior customer support for acomplete line of fuse protection products, and may even use theinformation to improve existing circuit protection products, identifynew product opportunities, and work closely with customers to solvecomplex problems in complicated electrical systems.

When implemented in easy to use, graphical interfaces and displays, theoverview and response dispatch system 118 can provide operating statusinformation to the customer at one location, a site technician atanother location, and to customer support personnel at a third locationwith real time information to manage circuit protectors in various typesof electrical systems and configurations. Thus, key personnel at theelectrical system site level, the key management or personnel at thecustomer level that is responsible for the electrical system, and keypersonnel for circuit product support and help at the manufacturer levelmay all be advised on a timely basis of actual operating conditions ofcircuit protectors in multiple respective electrical systems. Additionalparties, such as circuit protector retailers and distributors, couldalso be provided with circuit protector information as desired, and aspreviously mentioned, the overview and response dispatch system 118could be programmed to automatically order a replacement fuse, forexample, to replenish a fuse inventory as it is used.

E. The User Interface

FIGS. 30-46 illustrate aspects of an exemplary overview and responsedispatch system 118 and the user interface therefore, that in oneembodiment is a computer program or software embodied on a computerreadable medium and utilizing, for example, a Structured Query Language(SQL) with a client user interface front-end for administration and aweb interface for user input, access, and information retrieval andreports by service technicians and facilities management for electricalsystems. The overview and response dispatch system 118 may be webenabled and is run on a business-entity intranet or alternatively may befully accessed by individuals having an authorized access outside thefirewall of the business-entity through the Internet. In an exemplaryembodiment, the overview and response dispatch system is run in aWindows® NT environment or operating system that is commerciallyavailable from Microsoft Corporation of Redmond, Wash. The applicationis flexible and designed to run in various different environmentswithout compromising any major functionality.

FIG. 30 is a simplified block diagram of an exemplary embodiment of theoverview and response dispatch system 118 including a server system 720,and a plurality of client sub-systems, also referred to as clientsystems 722, connected to the server system 720. Computerized modelingand grouping tools, as described below in more detail, are stored in theserver system 720 and can be accessed by a requester at any one of theclient systems 722. In one embodiment, the client systems 722 arecomputers or other electronic devices including a web browser, such thatthe server system 720 is accessible to the client systems 722 using, forexample, the Internet.

The client systems 722 may be interconnected to the Internet throughmany interfaces including, for example, a network such as a local areanetwork (LAN) or a wide area network (WAN), dial-in-connections, cablemodems and special high-speed ISDN lines. The client systems 722 may beany device capable of interconnecting to the Internet including aweb-based phone, personal digital assistant (PDA), or other web-basedconnectable equipment or equivalents thereof. A database server 724 isconnected to a database 726 containing information on a variety ofmatters, as described below in greater detail. In one embodiment, thedatabase 726 is centralized and stored on the server system 720, and thedatabase 726 be accessed by potential users at one of client systems 722by logging onto the server system 720 through one of the client systems722. In an alternative embodiment, the database 726 is stored remotelyfrom server system 720 and may be non-centralized.

FIG. 31 is an expanded block diagram of an exemplary embodiment of aserver architecture of the overview and response dispatch system 118including the server system 720 and the client systems 722. The serversystem 720 includes the database server 724, an application server 728,a web server 730, a fax server 732, a directory server 734, and a mailserver 736. A disk storage unit 738 is coupled to the database server724 and the directory server 734. The servers 724, 728, 730, 732, 734,and 736 are coupled in a local area network (LAN) 740. In addition, asystem administrator's workstation 742, a user workstation 744, and asupervisor's workstation 746 are coupled to the LAN 740. Alternatively,workstations 742, 746, and 748 are coupled to LAN 740 using an Internetlink or are connected through an Intranet.

Each workstation, 742, 744, and 746 is a personal computer or otherelectronic device having a web browser. Although the functions performedat the workstations typically are illustrated as being performed atrespective workstations 742, 744, and 746, such functions can beperformed at one of many personal computers coupled to the LAN 740.Workstations 742, 744, and 746 are illustrated as being associated withseparate functions only to facilitate an understanding of the differenttypes of functions that can be performed by individuals having access tothe LAN 740.

The server system 720 is configured or adapted to be communicativelycoupled to various individuals via some of the client systems 722,including employees 750 associated with the overview and responsedispatch system 118 such as circuit protector manufacturer technicalsupport and assistance personnel, and to third parties 752 such asinstaller, technicians or maintenance personnel that are responsible foran electrical system to be monitored and communication with the serversystem 720 using, for example, an ISP Internet connection 754. Thecommunication in the exemplary embodiment is illustrated as beingperformed using the Internet, however, any other wide area network (WAN)type communication can be utilized in other embodiments. That is, theoverview and response dispatch system, and its operating algorithms andprocesses are not limited to being practiced using the Internet.

In an exemplary embodiment, any authorized individual having aworkstation 756, 768 can access the server system 720 via one of theclient systems 722. At least one of the client systems 722 includes amanager workstation 758 located at a remote location. Workstations 756and 758 may be personal computers or other electronic devices having aweb browser. Additionally, third party customers such as circuitprotector distributors or automated dispensing systems for replenishingcircuit protector inventories, may communicate with the server system720 via a workstation 760 having, for example, a web browser.

The fax server 732 may communicates with remotely located client systems722, including the workstations 756, 758 and 760. The fax server 732 mayuse, for example, a telephone link or cellular communications tower tocommunicate with the workstations and alert and summon designatedpersons for action and attention to the electrical system when circuitprotectors operate. The fax server 732 is configured or adapted tocommunicate with other client systems including but not limited to theworkstations 742, 744 and 746 as well for reporting purposes.

FIG. 32 is a flowchart illustrating an exemplary method or process 770utilized by the overview and response dispatch system 118. The technicaleffect of the processes and systems described herein is achieved wheninstallation information pertaining to the circuit protectors, statuselements, and communication devices in the signal transmission systemdescribed above is entered, transmitted, downloaded or otherwiseaccepted 772 by the overview and response dispatch system. Theinformation is stored in the aforementioned server system, and permitsincoming data signals from the gateway device to be decoded,interpreted, or processed by the overview and response dispatch system118 to convey information to end users as described below. In anexemplary embodiment, much of this information is supplied to thegateway configuration and monitoring algorithms 592 of the gatewaydevice 584 described above, and then communicated to the overview andresponse dispatch system 118. It is understood, however, that theinformation could be supplied to the overview and response dispatchsystem 118 through any of the workstations connected to the serversystem.

In one embodiment, the information accepted 772 corresponds to thevarious codes and information described above that are used to generatethe data packets and signal transmissions from the status elements tothe gateway, and accordingly the accepted information includes forexample, unique radio identifiers corresponding to each of the statuselement communications modules in the electrical system being monitored,serial numbers for the circuit protectors monitored by the statuselements, device type codes for various types of circuit protectors, alocation code for each circuit protector, wireless addresses forcommunication devices in the signal transmission system, an IP addressfor the gateway device, time/date stamps for incoming data signals fromthe gateway, a software revision code for the gateway applicationsoftware and/or the communications application loaded on the gatewaydevice, a hardware revision code for the gateway device, a data packetcount for an incoming message, an error count for incoming data packetsand messages, and error codes corresponding to different errorconditions for the status elements, the signal transmission system,and/or the overview and response dispatch system. Information regardingthe electrical system itself, including detailed site layout diagramsand schematics is also supplied and accepted 772 by the overview andresponse dispatch system. The information accepted 772 also includescustomer identifiers and contact information for the automated alertnotifications generated by the overview and response dispatch system.

Once the information circuit protector installation data is accepted772, the overview and response dispatch system displays 774 a site planand circuit protector overview for the electrical system beingmonitored. The site plan and circuit protector overview may includediagrammatic illustrations of the electrical system site and facilitieswhere the electrical system is located, the circuit protectorsassociated with the electrical system and their relative location in theelectrical system, circuitry and loads protected by the circuitprotectors, and operating status of the circuit protectors. The circuitprotectors may be grouped, categorized and presented to the user inmenu-driven form illustrated in the examples below.

The overview and response dispatch system awaits the receipt 776 of datasignals or messages from the gateway device, and if no messages arereceived 776, the overview and response dispatch system continues todisplay 774 the site plan and circuit protector overview.

If a message is received 776 from the gateway device, the overview andresponse dispatch system processes, decodes or interprets the messageand determines 778 whether the message corresponds to an alarmcondition, depending upon the contents of the message. If the overviewand response dispatch system determines 778 that the message does notcorrespond to an alarm condition, the data from the message is updated781 and the overview and response dispatch system returns to display 774the site plan and circuit protector overview, including any new orupdated information received in the message. For example, if the messagefrom the gateway indicates that a new circuit protector, status element,or circuit protector has been installed, or the signal transmissionsystem has been modified to include more or less repeater/routerelements, the site plan and circuit protector overview reflects suchchanges for inspection by users of the overview and response dispatchsystem. As another example, when the status elements collect operatingdata such as voltage, current or temperature readings from the circuitprotectors, and when such readings are included in the data messagesfrom the gateway device, such data and information may be displayed inconjunction with the site plan and circuit protector overview.

If the overview and response dispatch system determines 778 that themessage relates to an alarm condition, the overview and responsedispatch system generates 780 a notification alert and directly summonsand contacts designated personnel by any of the aforementioned methodsso that affected circuitry may be quickly evaluated. Various alarmconditions may be provided, and may indicate fault conditions in thecircuit protector monitoring and signal transmission components;threshold alarms when predetermined voltage, current or operatingtemperature conditions are approached; and opened circuitry alarms whenthe circuit protectors operate in use to isolate portions of thecircuitry. The alarm conditions may be categorized and ranked in termsof severity or urgency, and the overview and response dispatch systemmay respond differently to the various levels of alarm conditions.

Once the data messages are interpreted as alarm conditions andnotifications are generated 780, the overview and response dispatchsystem displays 782 the alarm condition so that interested system usersmay see the alarm condition detected in real time. If desired, anddepending upon the severity of the alarm condition, the overview andresponse dispatch system may initiate 785 special procedures to shutdown at risk systems, shut down certain machines, etc. as the alarmcondition warrants. The special procedures may include activatingauxiliary power to the affected loads corresponding to specific machinesor equipment, shutting down at risk systems or loads corresponding tospecific machines or equipment, saving key circuit data for analysis,etc. when the circuit protectors 108 operate to open portions of theelectrical system 100, and communicating such undertakings and actionsto designated personnel for further evaluation and response.

Initiation of the special procedures may entail communication with thegateway device that sent the alarm message to the overview and responsedispatch system, and allowing the gateway device to perform theprocedures at the electrical system site by communicating with, forexample, a computerized maintenance management system, a supervisorycontrol and data acquisition system, an industrial control andautomation system, an enterprise resource planning system, an electronicdata interchange system, a manufacturing resources planning system, asupply chain management system, automated disconnect switch controls,programmable logic controllers and the like that are operativelyconnected to auxiliary power supplies and power distribution equipment,and by other known control means familiar to those in the art.Alternatively, the initiation of special procedures could be implementedin the generation 780 of alarm notification wherein designated personnelare requested to take certain action to shut down specific equipment andloads, for example, until the alarm condition is rectified. Thus, indifferent embodiments, special procedures could be automaticallyundertaken by the gateway device and/or the overview and responsedispatch system without human action, or the gateway device and/or theoverview and response dispatch device may prompt a system user or systemcontact person to enact and perform the special procedures.

The overview and response dispatch system also displays 784 alarmmanagement options to users logged on to the system. Using the alarmmanagement options, users may acknowledge, clear, and annotate alarmevents, as well as to review alarm summaries and histories for laterstudy and analysis.

After the generation of notification and display of alarm conditions,the overview and response dispatch system awaits acknowledgment 786 ofthe alarm conditions by one or more users or responders. If the alarmnotification is not acknowledged within a reasonable time frame, theoverview and response dispatch system updates the alarm data 788,escalates 790 the alarm, and again generates another notification andsummons to designated personnel. The time frame to await acknowledgmentbefore escalating an alarm may be varied depending upon the severity ofthe alarm condition, and escalation of the alarm may be also be varied,or even eliminated, depending on the nature of the alarm condition.Escalation of alarms may result in additional or alternative persons orpersonnel being contacted and notified by the response dispatch system,a shortened time frame to acknowledge the alarm after additionalnotifications are sent, audio or visual alarm features to be activatedat one or more locations, or other means to garner attention to thesystem from one or more users so that affected circuitry may bere-energized or issues may be promptly addressed. Proactive managementof the electrical system in anticipation of circuit perturbations may befacilitated depending upon the sophistication of the alarm scheme used.

Once an alarm is acknowledged, the overview and response dispatch systemawaits to see whether the alarm is cleared 792 by one or more personsresponsible for the electrical system to let the overview and responsedispatch system know that the alarm condition has been attended to andthe alarm condition no longer exists. If the alarm is not cleared 792,the message data is updated 788 and the alarm escalated 790 prior togenerating 780 another notification of alarm condition.

Once the alarm is cleared 792, the message data is updated 794 and theoverview and response dispatch system returns to display the site planand circuit protector overview until another signal is received 776 fromthe gateway device. Information regarding alarm events, includingresponse times to acknowledge and clear the alarm conditions, arerecorded by the overview and response dispatch system for study andanalysis by facilities management. Reports may be compiled and generatedrelating to the performance of the electrical system, circuit protectorsassociated with the system, effectiveness of the status elements andsignal transmission system, responsiveness of personnel to the system,and other information of interest.

FIGS. 33-42 illustrate exemplary displays of a user interface for theoverview and response dispatch system 118 in an exemplary embodiment.

FIG. 33 is an example embodiment of a user interface displaying a logonscreen for a user of the overview and response dispatch system 118.Authorized system users may log onto the overview and response dispatchsystem 118 with a conventional username data field 800, password datafield 802, and a login button 804. Unauthorized system users areprevented from entering or accessing the overview and response dispatchsystem 118.

FIG. 34 is an example embodiment of a user interface displaying acircuit protector layout and overview screen that is presented to theuser after logging in. A navigation bar 810 is provided in the upperportion of the screen, and the navigation bar includes an overview link812 and an alarms link 814. A logout link 816 is provided adjacent thenavigation bar 810 for exiting the system.

A facility tree 818 is provided in one portion of the display andincludes a facility link 820, and sub-facility links 824, 826 and 828corresponding to different areas or portions of the larger facility. Inthe example shown, the larger facility is an industrial plant that isdivided into three distinct operating areas, namely a packaging area, apainting area, and a plating area. The areas may be located in the sameor different physical facility or building, and the user may see at aglance the facilities and sub-facilities being monitored.

A floor plan or site layout 830 is displayed for the selected facilitylink 820 or sub-facility links 824, 826 and 828. The site layoutillustrates the physical facility being monitored so that the user mayidentify relative locations of circuit protectors and navigate throughthe facility to address alarm conditions with minimal delay. Byselecting the facility or sub-facility links 822, 824, 826 and 828, theuser may see the monitored electrical system at various levels ofdetail.

An alarm notification area 832 is provided in the site plan and circuitprotector overview screen, and in an exemplary embodiment includes a mapdata field 834, an alarm area data field 836, a receiver name data field838, a time of alarm data field 840, a notification sent data field 842,and an alarm acknowledged data field 844 so that the user may see analarm condition and related information at a glance. The map data field834 directs the user to the site layout 830 being displayed. The alarmdata field 836 refers to the sub-facility link of interest. The receivername data field 838 refers to the electrical load being monitored oraffected within the alarm data field 836. Data fields 840, 842 and 844notify the user of the respective times of the alarm condition'soccurrence, notification of the alarm, and acknowledgment of the alarmby designated personnel.

A circuit protector summary 846 is also provided in the site plan andcircuit protector overview screen. The circuit protector summary 846 isprovided in tabular form in an exemplary embodiment and includes a fusecolumn 848 and a status column 849. Thus, in the example shown in FIG.34, there are four fuses associated with a machine in the painting areaof the industrial facility, and all four of the fuses are closed andoperational. Accordingly, the electrical system is operating normallyand the alarm data fields 840, 842 and 844 are empty.

A continue button 850 is provided to access more summary information,alarm conditions, site plans, etc. when the information may not bepresented on a single page or screen.

FIG. 35 illustrates the circuit protector layout and overview screenafter an alarm condition is indicated as the overview and responsedispatch system has received an alarm signal message from the gatewaydevice. The alarm notification area 832 now displays informationrelating to the alarm condition, and as shown in FIG. 35, the datafields 834, 836, 838, 840, 842 and 844 are populated or filled in by theoverview and response dispatch system to denote the respective map,alarm area, and receiver name associated with the alarm, and the time ofalarm, time of notification, and acknowledgment of the alarm. Inaddition, the circuit protector summary 846 summary now shows than oneof the circuit protector fuses, namely fuse 2 in the illustratedexample, has now opened and affected operation of the machine identifiedin the alarm notification area 832.

FIG. 36 is an example embodiment of a user interface displaying acircuit protector alarm management summary screen that may be accessedby the user, for example, by selecting the alarm link 814 in thenavigation bar 810 in FIG. 35.

The circuit protector alarm management summary screen includes thenavigation bar 810, and the facilities tree 818 described above. Whenthe user selects the sub-facility links, the tree 818 is expanded toshow the circuit protectors associated with the selected sub-facility.Thus, in the example shown, the packaging sub-facility link 824 isselected, and a machine link 851 and a panel link 852 are each presentedas icons that correspond to a machine and a circuit protector panellocated in the packing area. By selecting the machine or panel links 851and 852, the user may see the circuit protectors associated with themachine and panel in the electrical system being monitored.

The machine link 851 has also been selected in the example shown in FIG.36, and four circuit protectors 854 are shown graphically that areassociated with the machine. The fuse 2, indicated as open in thesummary area 846 in FIG. 35, has been selected on the circuit protectoralarm management summary screen of FIG. 36, and an alarm managementoverview 856 is presented to the user with corresponding information forthe opened circuit protector fuse 2 that has been identified.

The alarm management overview 856 includes date and time data fields 858and 860 that may be used to view alarms generated for the selectedcircuit protector fuse 2 within specific time and date parameters. Thus,alarms may studied to diagnose and troubleshoot underlying issues in theelectrical system that trigger the alarms. A fuse summary area 862 isprovided to display, for example, a group name that the selected circuitprotector belongs to, a zone name for an area of the electrical systemor facility area of the selected circuit protector, a location for theselected circuit protector, and the part number for the circuitprotector that identifies the type of the circuit protector that hasoperated. Thus, at a glance the user may learn the identity, locationand type of circuit protector that has generated an alarm, andaccordingly the user can quickly locate a replacement circuit protector,such as a fuse, and can efficiently locate the circuit protector,referring back to the site layout and circuit protector over screens ifnecessary by selecting the overview link 812 in the navigation bar 810.A picture 863 of the circuit protector type or model may be displayed tothe user to assist in locating a replacement circuit protector.

A tabular alarm status area 864 is provided that in one embodimentincludes an entity column 865, a status column 866, a time and datecolumn 868, and an explanation column 870. Each of the columns 865, 866,868 and 870 are populated by the overview and response dispatch systemwith information so that a user can quickly assess an alarm condition.

A view and respond to alarms link 872 is provided, and when the link 872is selected, a circuit protector alarm management options screen ispresented to the user as shown in FIG. 37. The alarm management optionsscreen is similar to the alarm management over screen shown in FIG. 36,but includes a view all alarms link 880, a view alarm details link 882,an acknowledge alarm link 884, a clear alarm link 886, an add note toalarm link 888, and a forward alarm link 890.

FIG. 38 is an example embodiment of a circuit protector alarm detailscreen that is accessible to a user by selecting the view alarm detailslink 882 in FIG. 37.

The circuit protector alarm detail screen includes a detail summary 900including an entity data field 902 corresponding to the load associatedwith the circuit protector of interest, an alarm severity data field904, a time and date data field 906 for the alarm, a brief explanationdata field 908 for the alarm, and a detailed explanation data field 910for the alarm so that the user may quickly learn key informationregarding the alarm condition.

An alarm action table 912 is also provided and includes an action column914, a note column 916, a date column 918, and a who acted column 920 toidentify the persons or persons that responded to an alarm condition.Thus, the user may quickly assess any action being taken or that hasbeen taken in response to an alarm. Notes can be automatically added bythe overview and response dispatch system, or manually entered byresponding personnel or system users to document circuit opening eventsor issues with the electrical system.

In an exemplary embodiment, the overview and response dispatch system isprogrammed to automatically notify and alert specific personnel, but auser may provide alert and notification to another person by selectingthe forward alarm link 890 if desired.

If the link 890 is selected, a circuit protector alarm forward window930 is presented to the user as shown in FIG. 39. The forward window 930includes a contact data field 932, a send button 934, and a cancelbutton 936. A phone number or email address may be typed into thecontact data field 932, and the buttons 934 and 936 may be used to sendor cancel a forwarded alarm. The window 930 may be used, for example, bya designated response person that is unable to respond to the alarm, anddesignated person may forward the message to someone else who mayrespond. The overview and response dispatch system may store theinformation entered in the contact data field 932 for future use or anescalated alarm if the person associated with the contact informationdoes not respond.

When a responder receives the message and is able to investigate thealarm condition, the responder may select the acknowledge alarm link884, and if so selected, a circuit protector alarm acknowledgementwindow 940 is displayed. In the window 940, the responder may enter anote in a note data field 942 if desired, and complete or cancel theacknowledgment by selecting ok or cancel buttons 944 and 946. Any noteentered by the responder is displayed in the alarm action table 912 ofthe alarm detail screen, and may also be displayed in the acknowledgeddata field 844 in the site plan and circuit protector overview screenshown in FIG. 35.

The responder may clear the alarm by selecting the clear alarm link 886,and if so selected, an alarm clearance window 950 is presented to theuser as shown in FIG. 41. The alarm clearance window 950 includes a notedata field 952, and ok and cancel buttons 954 and 956 for entering ordiscarding the note into the overview and response dispatch system. Theclearance note may be displayed to users in the alarm action table 912.

A user, whether the responder or otherwise, may add a note to an alarmfor future follow up or study by selecting the add note to alarm link888, and if so selected, an alarm note window 970 is presented to theuser as shown in FIG. 42. The alarm note window 970 includes a note datafield 972, and ok and cancel buttons 974 and 976 for entering ordiscarding the note into the overview and response dispatch system. Anysuch notes may be displayed to users in the alarm action table 912.

FIGS. 43-46 illustrate another exemplary embodiment of user interfacedisplays that may be implemented in the overview and response dispatchsystem.

FIG. 43 is an embodiment of a circuit protector layout and overviewdisplay that is presented to the user after logging on to the serversystem. A navigation bar is provided in the upper portion of the screen,and the navigation bar includes a monitor link 1000, an alarms link1002, a behaviors link 1004, a devices link 1006, and a reports link1008. A logout link 1010 is provided for exiting the system.

The monitor link 1000, when selected, may be used to access electricalsystem overviews and monitoring status for circuit protectors. Thealarms link 1002 may be selected to view archived alarm information. Thebehaviors link 1004 may be selected to access input screens and displaysto configure alarm behavior options for the overview and responsedispatch system, including selection of contact information and specificpersonnel to be contacted by the system, notification and alertpreferences and forwarding options, alarm acknowledgment and clearanceoptions, assignment of alarm severity levels, escalation options, andother user preferences for interacting with the overview and responsedispatch system. The devices link 1006 may be selected to access circuitprotector information, and the reports link 1008 may be selected by auser to enter report generation window, screens and displays wherein theuser may select report parameters, select formation and preferences,etc.

A facility tree 1012 is provided in one portion of the display andincludes a facility link 1014, and sub-facility or zone links 1016, 1018and 1020 corresponding to different areas or portions of the largerfacility. In the example shown, the larger facility is an motor plant,and three distinct operating areas, namely Zone 1, Zone 2, and Zone 3 ofthe motor plant are displayed. The areas or zones may be located in thesame or different physical facility or building, and the user may see ata glance the facilities and sub-facilities being monitored.

A floor plan or site layout 1022 is displayed for the selected facilitylink 1014 or sub-facility links 1016, 1018 and 1020. The site layoutillustrates the physical facility being monitored so that the user mayidentify relative locations of circuit protectors and navigate throughthe facility to address alarm conditions with minimal delay. Circuitprotector links 1023 are provided in the site layout 1022, and the links1023 may be selected by a user to see current status of circuitprotectors corresponding to the links 1023 in the site plan 1022. Byselecting the facility or sub-facility links 1014, 1016, 1018 and 1020the user may see the monitored electrical system and circuit protectorsat various levels of detail.

An alarm notification area 1024 is provided in the site plan and circuitprotector overview screen, and in an exemplary embodiment includes a mapdata field 1026, an alarm area data field 1028, a receiver name datafield 1030, a time of alarm data field 1032, a notification sent datafield 1034, and an alarm acknowledged data field 1036 so that the usermay see an alarm condition and related information at a glance. The mapdata field 1026 directs the user to the site layout 1022 beingdisplayed. The alarm area data field 1028 refers to the sub-facilitylink of interest. The receiver name data field 1030 refers to theelectrical load being monitored or affected within the alarm area datafield 1028. Data fields 1032, 1034 and 1036 notify the user of therespective times of the alarm condition's occurrence, notification ofthe alarm, and acknowledgment of the alarm by designated personnel.

A circuit protector summary 1038 is also provided in the site plan andcircuit protector overview screen. The circuit protector summary 1038 isprovided in tabular form in an exemplary embodiment and includes, forexample, a fuse column and a status column. Thus, in the example shownin FIG. 43, there are twelve Fuses associated with Zone 2 of the motorplant being monitored, and Fuses 1-4, 6-9 and 11 and 12 are closed andoperational, while Fuses 5 and 10 are indicated as open. By selectingone of the fuses in the summary 1038, the alarm data fields 1032, 1034and 1036 are populated in the alarm summary 1024 to provide informationregarding alarm conditions.

A zone alarm summary link 1040 is provided and may be selected to viewan alarm summary screen. An alarm severity data field 1042 is providedto quickly convey to the user the severity or urgency of an alarm state.

FIG. 44 is an example embodiment of a user interface displaying acircuit protector alarm management summary screen that may be accessedby the user, for example, by selecting the alarm summary link 1040 inFIG. 43.

The circuit protector alarm management summary screen includes thenavigation bar as before, and the facilities tree 1012 described above.When the user selects the links in the tree 1012, the tree 1012 isexpanded to show the circuit protectors associated with the selectedlink of the tree.

A tabular alarm status area 1050 is provided that in one embodimentincludes a zone column 1052, an alarm column 1054, a time and datecolumn 1056, and an event column 1058. Each of the columns 1050, 1052,1054 and 1056 are populated by the overview and response dispatch systemwith information so that a user can quickly assess an alarm condition.In the exemplary embodiment, the zone column 1052 indicates theoperation zones of the monitored facility where the alarm conditionsoccur, the alarm column 1054 indicates the severity of the alarmcondition, and the event column 1058 includes a brief description ofeach alarm condition. The zone column 1058 is populated with links thatmay be selected so that the user may see more specific detail for one ofthe alarms.

FIG. 45 is an example embodiment of a user interface displaying circuitprotector group information that may be accessed, for example, byselecting one of the links in the zone column 1052 of the status area1050 shown in FIG. 44. A group information summary area 1060 is providedthat includes a group name data field 1062, a zone data field 1064, acircuit protector location data field 1066, and a part number data field1068. The data fields 1062, 1064, 1066, and 1068 are populated by theoverview and response dispatch system so that the user may quicklyascertain the identity and location of a circuit protector associatedwith an alarm condition.

A fuse alarm history table 1070 is also provided that in an exemplaryembodiment includes a zone column 1072, an alarm column 1074, a time anddate column 1076 and an event column. Each of the columns 1072, 1074,1076 and 1078 are populated by the overview and response dispatch systemwith information so that a user can quickly assess an alarm condition.In the exemplary embodiment, the zone column 1072 indicates the circuitprotectors corresponding to the zone of interest in the monitoredfacility where the alarm conditions occur, the alarm column 1074indicates the severity of the alarm condition, and the event column 1078includes a brief description of each alarm condition. The zone column1072 is populated with links that may be selected so that the user maysee more specific detail for one of the circuit protectors.

FIG. 46 is an example embodiment of a user interface displaying acircuit protector alarm detail screen that may be accessed, for example,by selecting one of the links in the zone column 1072 of the alarmhistory table 1070 shown in FIG. 45. An alarm detail summary area 1080is provided that includes an entity data field 1082, and severity datafield 1084, a when it happened data field 1086, and a what it means datafield 1088. The entity data field identifies the circuit protector andits location for the corresponding alarm, the severity data field 1084indicates the severity of the alarm, the when it happened data field1086 indicates the timing of the alarm, and the what it means data field1088 provides a brief explanation of the alarm.

A fuse alarm action table 1094 is also provided that in an exemplaryembodiment includes an action column 1096, a note column 1098, a timeand date column 1100 and a who acted column 1102. Each of the columns1096, 1098, 1100 and 1102 are populated by the overview and responsedispatch system with information so that a user can quickly assess analarm condition. Alarm options links are provided, including a view allalarms link 1104, an acknowledge alarm link 1106, a clear alarm link1108, an add note to alarm link 1110, and a forward alarm link 1112. Thealarm options links and associated functionality is described above.

The above described displays and screens shown in FIGS. 33-46 may beused with as many circuit protectors as the circuit protector monitoringand signal transmission systems can accommodate, and in some systems thecircuit protectors may number in the thousands. The user interfacedisplays and screens, however, capably present voluminous amounts ofdata and circuit protector status detail in easy to use, graphical andtabular forms with intuitive links to quickly hone in on desiredinformation. The user interface displays may be implementedconventionally in a computer program embodied on a computer readablemedium and having segments of code or instructions executed by acomputer that correspond to the various functions and features describedabove for managing circuit protector information corresponding toelectrical systems. Providers of software programming and code segmentsand instructions for such purposes include, for example, SensorLogic ofDallas, Tex., and Questra of Redwood, Calif.

It is understood that additional segments of code corresponding toadditional displays, links, tables, graphics, information, and indiciamay be provided in further embodiments, and further that not all of theexemplary information provided in the above-described displays andscreens need be used in some embodiments of the invention. The userinterface displays may be varied to suit the needs of specificelectrical systems, facility managers, and for different types ofcircuit protectors. When the user interface displays are implemented ona network-based system as described above, the system may flexiblypresent information to multiple users simultaneously, and throughmenu-driven graphical displays and information links, system users mayquickly access needed information to properly manage the electricalsystem, respond to alarm conditions with minimal delay, and accessperformance data and event histories for study and analysis.

While the user interface described above is illustrated in the contextof overcurrent protection fuses and data therefore in an electricalsystem, the user interface may be adapted to include data fields, links,graphics, and tables for managing and responding to various operatingconditions and issues for other types of overcurrent circuit protectorsystems such as circuit breakers and switches. For example, in a circuitbreaker system, the overview and response dispatch system 118 could beemployed to monitor and verify operating states of the breakers,maintenance activities for the breaker system, identification of trippedbreakers and their location in the system, recording of event historieswhen the breakers are tripped, etc., and the user display may be presentsuch information to a user in real time so that circuit breaker andelectrical systems can be addressed promptly without having to gatherinformation from various other sources.

F. A Multifunctional Response Tool

To further facilitate rapid response and attention to circuit protectoralarm conditions and alerts and summons to investigate an issueidentified by the management system 112, in one embodiment amultifunctional response tool is provided.

FIG. 47 is a schematic diagram of an exemplary circuit protectorresponse tool 1140 that may be used with the overview and responsedispatch system 118 to quickly investigate and restore affectedcircuitry due to operation of a circuit protector 108. The circuitprotector in one example is a fuse 1142 having a fuse body 1144 locatedin a panel 104 in the electrical system 100. The fuse 1142 has endterminals 1146, 1148 and a primary fuse element 1150 extendingtherebetween and defining an interruptible current path to open thecircuit through the fuse 1142 upon a specified current condition in theelectrical system 100 and isolating a portion of the electrical system100. A status element 110 is associated with the fuse 1142 and monitorsan operational sate thereof, and when the primary fuse element 1150 hasopened, the status element 110 signals the overview and responsedispatch system 118 as described above. While one circuit protector 108is shown in FIG. 47, it is appreciated that the tool 1140 may be used inconjunction with a plurality of circuit protectors 108 that aremonitored by the overview and response dispatch system 118.

The tool 1140 may be used by maintenance personnel, electricians,technicians, and others that are called upon to respond to an alarmcondition. The tool 1140, as explained below, alleviates difficultiessuch personnel face in transporting, accessing, and utilizing a varietyof tools and documents conventionally needed to effectively respond toan electrical system disturbance.

For example, service technicians have conventionally needed, among otherthings, circuit schematics of the electrical system and site plans of apower distribution facility to orient himself or herself within theelectrical system and locate specific circuit protectors and loads inthe system, metering tools to check voltage and current readings atcertain points in the electrical system, and communication devices tospeak with other technicians and/or to communicate with components ofthe electrical systems when responding to an electrical systemdisturbance. Conventionally, the technician repeatedly handles suchdevices and documents when responding to a disturbance, together with avariety of other hand tools, and frequently must handle the devices incramped or hard to reach areas in an electrical system. The devices andtools may be carried on a tool belt, but repeatedly deploying multipledevices from the tool belt and securing them to the tool belt when notin use, can be a time consuming and inconvenient task. Managing such amultiplicity of such tools, devices and documents often contributes totime delay in successfully responding to the disturbance and restoringor resetting the circuitry to normal operation. This is especially truewhen a single technician must respond to a disturbance.

To alleviate such difficulties, the tool 1140 is provided thatfacilitates navigation through a complex electrical system, checking ofappropriate circuitry and confirming the identity of circuit protectors,communicating information to other responsible parties, and interactionwith the overview and response dispatch system.

In an exemplary embodiment, the tool 1140 is a multifunctionalelectronic device and is provided in a compact protective housing 1152that may be easily transported and carried by a user navigating throughdifferent portions of the electrical system being monitored to specificsites or locations of the circuit protectors installed in the electricalsystem. The housing 1152 may include, for example, a belt clip to attachthe housing 1152 to a tool belt during periods of non-use. The housing1152 surrounds, encloses and protects a plurality of sub-devices that inan exemplary embodiment include a controller device 1154, an inputinterface 1156, a display device 1158, a communications device 1160, apositioning device 1162, a scanner device 1164, a digital multimeterdevice 1166, a thermometer device 1168, an entertainment device 1170, anaudio/video device 1172, an instruction device 1174, and an imagingdevice 1176. An on board power supply 1180, such as a rechargeablebattery in one embodiment, powers the controller 1154 and thesub-devices 1156, 1158, 1160, 1162, 1164, 1166, 1168, 1170, 1172, 1174,1176 and 1178. The sub-devices 1156, 1158, 1160, 1162, 1164, 1168, 1170,1172, 1174, 1176 and 1178 are mounted to or secured within the housing1152 so that the functions of the sub-devices are integrated into asingle tool 1140, thereby avoiding transport and handling of multipledevices when working in the electrical system to troubleshoot circuitprotectors and restore affected circuitry when they operate.

The controller 1154 may be a microcontroller having a microprocessor orequivalent electronic package that receives inputs and generates outputsto the various sub-devices 1156, 1158, 1160, 1162, 1164, 1166, 1168,1170, 1172, 1174, 1176 and 1178 in use.

The input interface 1156 permits the user to select operating modes anduser preferences or options for the tool 1140, and switching among thefunctions of the sub-devices 1156, 1158, 1160, 1162, 1164, 1168, 1170,1172, 1174, 1176 and 1178 when using the tool 1140. The interface 1156may include an alphanumeric keyboard and may be optimized for use with aminimal number of key strokes. For example, the interface 1156 may be avirtual keyboards or pen-based input system, a keyboard device that maybe used substantially through the use of thumbs, or other equivalentinterfaces common to hand-held personal digital assistant (PDA),personal information management (PIM) and other electronic organizers.

The display device 1158 may be for, example, a dot matrix liquid crystaldisplay (LCD), a touch sensitive display, or other equivalent displayfor presenting information to the user. The display may presentgraphics, text, links and other indicia and information to the user in aknown manner. Using the interface 1156 and the display 1158, the usermay select operating modes of the tool 1140, enter data inputs, andselect user preferences, options and features of the tool 1140.

The communications device 1160, may be a cellular phone or two way pagerdevice providing voice or text messaging communication with, forexample, the overview and response dispatch system 118. The tool 1140may be a designated contact for receiving an automated alert andsummons/alarm notification from the overview and response dispatchsystem 118. Thus, when a summons/alarms notification is received by thecommunications device 1160, circuit protector information such aslocation data corresponding to a circuit protector in the electricalsystem, and identification information corresponding to the circuitprotector may be specifically presented to the user on the display 1158.

The tool 1140 may include a web browser 1172 so that, when anotification is received at the tool 1140, the user may log on to theoverview and response dispatch system to view alarm details and otherinformation, such as the site plans in the user interface describedabove to quickly respond to the notification. The communications device1160 also facilitates communication between a user of the device andother persons, such as other site technicians, facilities management, ortechnical support of a circuit protector manufacturer.

In a further and/or alternative embodiment, the communications device1160 may include a Bluetooth device or equivalent thereof thatautomatically communicates with nearby devices and systems according toknown compatibility standards and technology. In such an embodiment, thecommunications device 1160 may automatically connect with nearby circuitprotectors, appliances and equipment using modulated signals as the tool1140 is moved through the electrical system, and the communicationsdevice may automatically request and receive associated data, andtransmit such data to the overview and response dispatch system 118.

The positioning device 1162 may be a global positioning module that candirect the user to a specific site in the electrical system, and topinpoint the exact location of the circuit protector 108 in theelectrical system, as well as to pinpoint the user's relative locationin the electrical system when operating the tool 1140. The position ofthe circuit protector of interest, and a responder's location relativeto the circuit protector of interest, can be monitored and displayed bythe overview and response dispatch system 118, and accessed by the userthrough the communications device 1160 and the display 1158. Otherpositioning and locating technologies could be used alternativeembodiments to sense a user's position in the electrical system and toprovide feedback to the user to assist in quickly locating circuitprotectors identified by the overview and response dispatch system 118.

The scanner device 1164 may be provided to collect and confirm data andinformation for the overview and response dispatch system 118. Forexample, the scanner device 1164 may be a document scanning device thatmay scan, read and process documents for upload to the overview andresponse dispatch system or for electronic access by the user whenworking in the electrical system. Documents scanned may includeprocedure manual materials, site plan information, circuit protectorinformation, information regarding the electrical system and itsoperating loads, employee contact information, calendar information, orother items of interest.

In a further and/or alternative embodiment, the scanner device may be abar code scanner, an RFID scanner, or equivalent thereof that cooperateswith a bar code label, RFID tag, or other information element 1165associated with the circuit protector. The information element mayinclude circuit protector information such as a circuit protector serialnumber provided by the manufacturer, a device type code for the circuitprotector, a location or address code for the circuit protector, apower/control code for the status element, an equipment identificationcode for the electrical system load associated with the circuitprotector, and state parameter codes such as testing codes, faultscodes, and codes pertaining to operating conditions of the circuitprotector and/or circuitry associated with the status elements. In suchan embodiment the scanner device 1164 may be used to scan the circuitprotector 108 once it is located in the electrical system, and the tool1140 and/or the overview and response dispatch system 118 may confirmthat the circuit protector 108 has been correctly identified. Thescanner device 1164 may likewise be used to scan the informationelements 1165 as information inputs to the overview and responsedispatch system 118 or the associated gateway device 584 when existingequipment, for example, includes bar code labels and the like withcircuit protector information.

The multimeter device 1166 is adapted for measuring a number ofparameters generally needed for service, troubleshooting, andmaintenance applications for the circuit protectors 108 and theelectrical system 100. The parameters may include AC voltage andcurrent, DC voltage and current, and resistance or continuity. Otherparameters such as frequency, capacitance, temperature may be readilyadded to meet the requirements of the particular application.

In one embodiment, the multimeter device 1166 may be a general purposemultimeter device including an internal current shunt having a knownresistance that is inserted in the current path of the circuit protector108 with for example, leads or test probes L₁ and L₂. The voltage dropacross the current shunt is may be measured to determine the current.Alternatively, the multimeter device 1164 may be a clamp-on multimeteremploying an integral current clamp which senses the current in thecurrent path without having to cut or break the current-carrying paththrough the fuse. The current clamp may be closed around the circuitprotector 108 or conductors, such as wires or bus bars connected to thecircuit protector 108 to sense the magnetic field created by the currentflow. The current clamp may provide a voltage signal for measurement bythe multimeter device 1164 which calculates and displays the measuredcurrent level. The multimeter device may be configured or adapted toautomatically select a proper measurement range for display to the user.

To facilitate multimeter functionality, the input interface 1156includes selectors, buttons, keys or pads, and input terminals requiredto select and exercise the available features. For example, the inputinterface 1156 may include input selectors for different currentmeasurement ranges, and input selectors for AC and DC voltagemeasurements. Two input connectors for current measurements in additionto the voltage measurement input and a common input may be provided.“Softkeys” and changing the legend on the display 1158 may reduce thenumber of buttons needed, wherein a new legend is displayed when the keyfunction is to be changed.

The thermometer 1168 is a known temperature sensing device that may beused with the leads or test probes L₁ and L₂ to sense an operatingtemperature of the circuit protector 108 and evaluate its operatingcondition.

The entertainment device 1170 may be adapted to process compressed audioand/or video streams for example, and allow the user to listen to music,watch videos, play games, check news and sports updates, etc. in a knownmanner. Entertainment media may be downloaded to the device 1170 orprovided on plug-in cards or disks.

The audio/video device 1172 may be adapted to record audio, stillimages, and/or video in a known manner. Camera technology and recordingdevices for such purposes are known and may be implemented in the module1172. Recorded audio, still images, and video may be communicated to theremote operation dispatch system 118 for access by remote users,facilities managers, etc. for oversight purposes, or for diagnostics andassessment purposes after alarm conditions are rectified.

The instruction device 1174 may be provided for training purposes, forexample, and may include procedure manuals, system manuals, audio andvisual instruction and demonstration materials, and help functions fortechnicians when installing, troubleshooting or responding to thesensing and monitoring components, signal transmission components, theoverview and response dispatch system 118, and various error conditionsfor system components. Media for the instruction device 1174 may bedownloaded to the device 1174 or provided on plug-in cards or disks, andthe media may be customized for particular electrical systems andpersonnel. Using the instruction device 1174, users of varyingexperience may be guided through proper installation and connectionprocedures, diagnostic procedures, and response procedures, and becausethe instruction device 1174 is local to the response tool 1140, theinformation may be accessed offline without requiring a connection tothe overview and response dispatch system 118. The user is therefore notdependent upon access to the operation system 118 to complete necessarytasks.

The imaging device 1176 is adapted to provide, for example, thermalimaging for inspection of the electrical system in a known manner.Infrared techniques and equivalents thereof may be used, for example, togenerate temperature profiles and data, and such may be useful toquickly assess operation conditions of circuitry and identify problemareas when personnel arrive on the scene in response to an alertnotification from the overview and response dispatch system 118.

An analyzer device 1178 may be provided and accessed by the user tofurther evaluate alarm conditions or operating parameters of theelectrical system and the circuit protectors. The analyzer device may befor example, a known spectrum analyzer device operable in a knownmanner.

While a variety of sub-devices 1156, 1158, 1160, 1162, 1164, 1166, 1168,1170, 1172, 1174, 1176 and 1178 adapted for different functions of theresponse tool 1140 have been described, it is appreciated that not allof the sub-devices need be included in some embodiments. Rather, thesub-devices may be provided in desired combinations for specific users.Additional functions and sub-devices may likewise be included in furtherand/or alternative embodiments.

FIG. 48 is a an exemplary flowchart for a method 1200 of responding to acircuit protector alert using the tool shown in FIG. 47. The method 1200allows efficient re-energization of affected circuitry in an electricalsystem when a circuit protector operates to isolate one portion of anelectrical system from another portion of the electrical system.

The method includes providing 1202 a status element proximate to therespective circuit protectors of interest in the electrical system,providing 1204 an electronic management system responsive to the statuselements as explained above, and providing 1206 the multifunctionalhandheld response tool 1206. When the status elements are installed andthe management system is operating, the operating states of the circuitprotectors are monitored and sensed 1208 using any of the aforementionedstatus elements and monitoring techniques. Based upon the sensed stateof the circuit protectors, a data signal is transmitted 1210 from atleast one of the status elements to a remote location in any mannerdescribed above when one of the circuit protectors has operated toisolate a portion of the electrical system. The data signal includes atleast an identification code and an address code to identify thelocation of the operated circuit protector.

In response to the transmitted signals, the management system generates1211 an alert and summons to responsible personnel of the operatedcircuit protector and the location of the operated circuit protector.The alert and summons is received 1212 with the handheld,multifunctional response tool carried by the user responsible forresponding to the alert. The user may acknowledge 1214 the alert andsummons. If necessary, the user may forward 1215 the alert to anotherparty for response.

Once the message is received 1212, the identity and location of thecircuit protector associated with the alert is displayed to the user viathe display of the tool, and the user may proceed to find 1216 thecircuit protector in the electrical system and move to its physicallocation, or may proceed to log on 1217, also using the tool, to theoverview and response dispatch system to obtain further detail andinformation regarding the circuit protector of interest. Once logged on,the user may obtain and review alarm condition information, includingthe alarm summary displays, alarm detail displays, and an alarm optionsdisplays described above. The user may additionally be presented withspecific information regarding potential hazards in the location of thecircuit protector, and be given information regarding precautions thatshould be taken and personal protection equipment that should beutilized when responding to an operated circuit protector.Alternatively, such information may be provided in the initial messagereceived 1212 with the tool.

The positioning device of the tool may be consulted to find or locatethe circuit protector in the electrical system and arrive at itsphysical location, or the maps, site plans and information may beobtained from the overview and response dispatch system to aid infinding the circuit protector. Once found, the identity of the circuitprotector may be confirmed 1218 using the scanner device of the tool, orinformation obtained from the overview and response dispatch system.

After finding and/or confirming the identity of the circuit protector,the operating state thereof may be checked 1220 using the multimeterfunction of the tool, the tool thermometer 1168, the imaging device 1176or the spectrum analyzer 1178 to verify or confirm 1222 the operatingstate of the circuit protector. The user may then proceed to rectify orrepair the alert condition, replace the circuit protector or otherwiserestore 1226 the circuit to its normal operating condition.

Using the tool 1140 and the method 1200, the user need not gathermultiple devices and documents to take to the circuit protectorinstallation site to investigate the alert or alarm conditions received.Rather, the user may simply proceed to accomplish the task at hand withthe utmost expediency and with instant access to information needed toefficiently redress the alarm condition or alert. Multiple tools 1140could be provided to perform the method 1200 for simultaneous responseto multiple alarm conditions by different users, operators orresponders.

G. System Adaptations

The systems and processes described above are not limited to thespecific embodiments described herein. Components of each system andeach process can be practiced independent and separate from othercomponents and processes described herein. Each component and processalso can be used in combination with other components, systems andprocesses.

For example, the foregoing circuit protector monitoring and managementsystem 112 may be implemented in whole or in part to meet the needs of aparticular electrical system 100 or for cost management reasons. Inother words, the management system 112 may not include all of thedescribed components, or perform all of the described functions setforth above. That is, the management system 112 may be configured oradapted, for example, to sense and record circuit protector operationand performance without communicating an operating state or condition ofthe circuit protector to a remote device for real time display ofcircuit protector operation. In such an embodiment, the circuitprotector could be removed from the electrical system and informationcould be read from the circuit protector at another location, or areader, transponder or communications device, such as the describedresponse tool, could be brought to the location of the circuit protectorto obtain information therefrom.

As another example, the management system 112 could identify anddetermine operational status and data regarding the circuit protectorand circuitry and communicate and transmit data to the overview andresponse dispatch system 118, but not communicate with an inventorymanagement system. Further, the management system 112 could beimplemented to alert and dispatch response to circuit protector openingevents, without enabling the diagnostic and troubleshooting aspects ofthe management system as described. Likewise, the tool can be providedwith varying degrees of functionality for cost management reasons, andin certain installations and embodiments may be entirely omitted. Itshould now be apparent that the system components may be mixed andmatched to generate varying systems which obtain the benefits of thepresent invention to varying degrees.

One embodiment of a circuit protector system is described herein thatincludes at least one overcurrent circuit protector defining aninterruptible current path therethrough upon an occurrence of specifiedcurrent conditions through the interruptible current path; a statuselement associated with the circuit protector and adapted to monitor anoperating state of the current path; and an electronic management systemin communication with the status element, wherein the management systemis adapted to automatically alert and summon responsible personnel whenthe circuit protector has operated to open the circuit path, andidentify the location of the operated circuit protector.

Optionally the status element wirelessly communicates with themanagement system, and the status element may be selected from the groupof an RFID chip, a transmitter, a smart card, a mechanical actuator, andan optically activated indicating circuit. The status element mayinclude a monitoring module mechanically and electrically connected toterminal elements of the circuit protector at a location exterior to thecircuit protector, the module adapted for retrofit installation to thecircuit protector. The status elements may collect data and informationregarding the operation of the circuit protector, thereby facilitatingdiagnostic evaluation and troubleshooting of an electrical system.

The management system may optionally be adapted to alert and summonpersonnel by a remote device, the remote device being selected from thegroup including a computer, a pager, a dispatcher, a cellular phone, afacsimile device, a response tool, a hand held electronic device, andcombinations thereof. A communications link may optionally interface thestatus element and the management system, and the communications linkmay be selected from the group including a hard-wired communicationslink, an optical communications link, a network communications link, awireless communications link, a satellite communications link, a powerline frequency carrier, and combinations thereof.

The status element is optionally adapted to identify operation of thecircuit protector via at least one of a polling method, currentmonitoring, voltage monitoring, temperature sensing, vibration anddisplacement sensing, mechanical stress and strain sensing, acousticalemission sensing, noise sensing, thermal imagery and thermalography,electrical resistance sensing, pressure sensing, humidity sensing andvideo surveillance. The management system electronically optionallycommunicates with at least one remote system, the at least one remotesystem being selected from the group of a circuit protector inventorymanagement system to replenish a depleted circuit protector inventory asinventory is used, a computerized maintenance management system, asupervisory control and data acquisition system, an industrial controland automation system, an enterprise resource planning system, anelectronic data interchange system, a manufacturing resources planningsystem, and a supply chain management system. At least onerouter/repeater element may optionally receive an RF signal from themonitoring module, the router/repeater element forwarding the RF signalto an intelligent gateway device that processes the RF signal andconverts the signal to a predetermined message protocol that isdifferent from a protocol of the RF signal.

The management system may be responsive to a data message, the datamessage optionally including multiple bits selected from the groupincluding a unique radio identifier, a manufacturer serial number forthe status element, a device type code for the circuit protector, alocation or address code for the circuit protector, a power/controlcode, an equipment identification code, a testing code, a fault code, acustomer code, a temperature code, a vibration code, a displacementcode, a mechanical stress code, a mechanical strain code, an acousticalemission code, a noise code, a thermal imagery code, an electricalresistance code, a pressure code, a humidity code and a video code. Themanagement system may optionally be adapted to identify a monitoringmode of the status elements, wherein the monitoring mode is selectedfrom the group including a registered status, a discovered status, anactivated status, a suspended status, a deactivated status, and anoffline status.

A multifunctional response tool may optionally provided and communicatewith the management system. The tool may include multiple devicesselected from the group of a communications device, a positioningdevice, a scanner device, a multimeter device, and a thermometer device.The management system may be adapted to convey information regardingpotential hazards in the location of the circuit protector, andprecautions to be utilized when responding to an operated circuitprotector.

In another embodiment, a circuit protector system includes a pluralityof overcurrent circuit protectors, each of the overcurrent circuitprotectors defining an interruptible current path therethrough upon anoccurrence of specified current conditions through the interruptiblecurrent path. A status element associated with each of the circuitprotectors, and each of the status elements is adapted to monitor anoperating state of the respective current path, and at least one of thestatus elements adapted to transmit a data signal when one or more ofthe current paths are interrupted as the circuit protectors operate. Agateway device is adapted to receive the data signal from the at leastone status element, and an electronic management system is incommunication with the gateway device, wherein the management system isadapted to alert and summon responsible personnel when the circuitprotector has operated to open the circuit path, and identify thelocation of the operated circuit protector.

Optionally, the electronic management system is adapted to initiatespecial procedures in response to operation of the circuit protectors.The status element includes a monitoring module mechanically andelectrically connected to terminal elements of the circuit protector ata location exterior to the circuit protector, and the module may includea radio frequency (RF) transmitter. The monitoring module may alsoinclude a voltage sensor detecting a voltage change across the circuitprotector when the current path is interrupted, the voltage changetriggering transmission of the data signal to the gateway device. Themanagement system may be adapted to alert and summon personnel via atleast one of an email notification, a fax notification, a pagernotification, a web page notification, and a voice notification.

In another embodiment, a circuit protector system includes a pluralityof overcurrent protection fuses, each of the overcurrent protectionfuses having a primary fuse element extending between first and secondterminal elements, the primary fuse elements defining an interruptiblecurrent path therethrough upon an occurrence of specified currentconditions through the primary fuse element. A status element isassociated with each of the circuit protectors, and the status elementsinclude monitoring modules adapted to sense a voltage differentialacross the first and second terminal elements of the respective fuses.At least one communications module includes a low power radio frequency(RF) transmitter, and the communications module adapted to generate anRF data signal when a voltage drop across the first and second terminalelements is sensed. A plurality of radio repeater/router elements areadapted to forward RF data signals from any of the status elements to anintelligent gateway device adapted to receive data signals forwardedthrough the repeater/router elements. An overview and response dispatchsystem in communication with the gateway device, wherein the overviewand response dispatch system is adapted to alert and summon responsiblepersonnel of one or more operated fuses, and identify the locations ofthe operated fuses for replacement to efficiently re-energize affectedcircuitry.

Optionally, the data signal includes a digital radio frequency signal.The management system may be adapted to await acknowledgement of analert to responsible personnel, and if no acknowledgment is received ina predetermined time period, re-alert and re-summon responsiblepersonnel of the operated fuses and identify the locations of theoperated fuses. The electronic management system may also be adapted toinitiate special procedures in response to operation of the circuitprotectors, the special procedures selected from the group of activatingauxiliary power, shutting down equipment, and saving circuit data foranalysis.

In another embodiment, a method of efficiently re-energizing affectedcircuitry in an electrical system when a circuit protector operates toisolate one portion of an electrical system from another portion of theelectrical system. The method includes providing a status elementproximate to the respective circuit protectors of interest, and anelectronic management system responsive to the status elements; sensing,using the status elements, an operating state of the circuit protectorwhen installed in the electrical system; and based upon the sensed stateof the circuit protectors, communicating a data signal from at least oneof the status elements to a remote location when one of the circuitprotectors has operated to isolate a portion of the electrical system.The data signal includes at least an identification code and an addresscode to identify the location of the operated circuit protector.Optionally, the method further includes generating a replacement orderfrom the electronic management system to replenish a fuse inventory whenthe operated fuse has been replaced.

In another embodiment, a circuit protector system includes means forsensing an operating state of a plurality of circuit protectors in anelectrical system; means for communicating a data signal correspondingto a sensed operation of one or more of the circuit protectors, therebyisolating at least one portion of the electrical system from anotherportion of the electrical system; means for receiving the data signalcorresponding to a sensed operation of one or more of the circuitprotectors; and means for generating an alert and summons to responsiblepersonnel, without human intervention, of the type and location ofoperated circuit protectors to permit efficient re-energization of thecircuitry. Optionally, the means for communicating includes means fortransmitting a low power wireless signal.

While the invention has been described in terms of various specificembodiments, those skilled in the art will recognize that the inventioncan be practiced with modification within the spirit and scope of theclaims.

1. A circuit protector system comprising: at least one overcurrentcircuit protector defining an interruptible current path therethroughupon an occurrence of specified current conditions through theinterruptible current path; a status element associated with the circuitprotector and adapted to monitor an operating state of the current path;and an electronic management system in communication with the statuselement, wherein the management system is adapted to automatically alertand summon responsible personnel when the circuit protector has operatedto open the circuit path, and identify the location of the operatedcircuit protector.
 2. The system of claim 1, wherein the status elementwirelessly communicates with the management system.
 3. The system ofclaim 1, wherein the status element comprises an RFID chip.
 4. Thesystem of claim 1, wherein the status element comprises a transmitter.5. The system of claim 1, wherein the status element comprises a smartcard.
 6. The system of claim 1, wherein the status element comprises amechanical actuator.
 7. The system of claim 1, further comprising anoptically activated indicating circuit.
 8. The system of claim 1,wherein the status element collects data and information regarding theoperation of the circuit protector, thereby facilitating diagnosticevaluation and troubleshooting of an electrical system.
 9. The system ofclaim 1, wherein the management system is adapted to alert and summonpersonnel by a remote device, the remote device being selected from thegroup comprising a computer, a pager, a dispatcher, a cellular phone, afacsimile device, a response tool, a hand held electronic device, andcombinations thereof.
 10. The system of claim 1, further comprising acommunications link interfacing the status element and the managementsystem, the communications link being selected from the group comprisinga hard-wired communications link, an optical communications link, anetwork communications link, a wireless communications link, a satellitecommunications link, a power line frequency carrier, and combinationsthereof.
 11. The system of claim 1, wherein the status element isadapted to identify operation of the circuit protector via at least oneof a polling method, current monitoring, voltage monitoring, temperaturesensing, vibration and displacement sensing, mechanical stress andstrain sensing, acoustical emission sensing, noise sensing, thermalimagery and thermalography, electrical resistance sensing, pressuresensing, humidity sensing and video surveillance.
 12. The system ofclaim 1, wherein the management system electronically communicates withat least one remote system, the at least one remote system beingselected from the group of a circuit protector inventory managementsystem to replenish a depleted circuit protector inventory as inventoryis used, a computerized maintenance management system, a supervisorycontrol and data acquisition system, an industrial control andautomation system, an enterprise resource planning system, an electronicdata interchange system, a manufacturing resources planning system, anda supply chain management system.
 13. The system of claim 1, wherein thestatus element comprises a monitoring module mechanically andelectrically connected to terminal elements of the circuit protector ata location exterior to the circuit protector, the module adapted forretrofit installation to the circuit protector.
 14. The system of claim13, wherein the monitoring module comprises a radio frequency (RF)transmitter.
 15. The system of claim 14 further comprising at least onerouter/repeater element receiving an RF signal from the monitoringmodule, the router/repeater element forwarding the RF signal to anintelligent gateway device that processes the RF signal and converts thesignal to a predetermined message protocol that is different from aprotocol of the RF signal.
 16. The system of claim 1 wherein themanagement system is adapted to alert and summon personnel via at leastone of an email notification, a fax notification, a pager notification,a web page notification, and a voice notification.
 17. The system ofclaim 1, wherein the management system is responsive to a data message,the data message comprising multiple bits selected from the groupcomprising a unique radio identifier, a manufacturer serial number forthe status element, a device type code for the circuit protector, alocation or address code for the circuit protector, a power/controlcode, an equipment identification code, a testing code, a fault code, acustomer code, a temperature code, a vibration code, a displacementcode, a mechanical stress code, a mechanical strain code, an acousticalemission code, a noise code, a thermal imagery code, an electricalresistance code, a pressure code, a humidity code and a video code. 18.The system of claim 1, wherein the management system is adapted toidentify a monitoring mode of the status elements, and wherein themonitoring mode is selected from the group comprising a registeredstatus, a discovered status, an activated status, a suspended status, adeactivated status, and an offline status.
 19. The system of claim 1,further comprising a multifunctional response tool communicating withthe management system, the tool comprising multiple devices selectedfrom the group of a communications device, a positioning device, ascanner device, a multimeter device, a thermometer device, anentertainment device, an audio/video device, an instruction device, animaging device, and a spectrum analyzer device.
 20. The system of claim1, wherein the management system is adapted to convey informationregarding potential hazards in the location of the circuit protector,and precautions to be utilized when responding to an operated circuitprotector.
 21. A circuit protector system comprising: a plurality ofovercurrent circuit protectors, each of the overcurrent circuitprotectors defining an interruptible current path therethrough upon anoccurrence of specified current conditions through the interruptiblecurrent path; a status element associated with each of the circuitprotectors, each of the status elements adapted to monitor an operatingstate of the respective current path, and at least one of the statuselements adapted to transmit a data signal when one or more of thecurrent paths are interrupted as the circuit protectors operate; agateway device adapted to receive the data signal from the at least onestatus element; and an electronic management system in communicationwith the gateway device, wherein the management system is adapted toalert and summon responsible personnel when the circuit protector hasoperated to open the circuit path, and identify the location of theoperated circuit protector.
 22. The system of claim 21, wherein thestatus elements communicate wirelessly with the gateway device.
 23. Thesystem of claim 21, wherein the electronic management system is adaptedto initiate special procedures in response to operation of the circuitprotectors.
 24. The system of claim 21, wherein the status elementcomprises a monitoring module mechanically and electrically connected toterminal elements of the circuit protector at a location exterior to thecircuit protector, the module adapted for retrofit installation to thecircuit protector.
 25. The system of claim 21, wherein the monitoringmodule comprises a radio frequency (RF) transmitter.
 26. The system ofclaim 25, further comprising at least one repeater/router elementreceiving an RF signal from the monitoring module, the repeater/routerelement forwarding the RF signal to the gateway device, the gatewaydevice processing the RF signal and converting the signal to apredetermined message protocol that is different from a protocol of theRF signal.
 27. The system of claim 24, wherein the monitoring modulecomprises a voltage sensor detecting a voltage change across the circuitprotector when the current path is interrupted, the voltage changetriggering transmission of the data signal to the gateway device. 28.The system of claim 21, wherein the management system is adapted toalert and summon personnel via at least one of an email notification, afax notification, a pager notification, a web page notification, and avoice notification.
 29. The system of claim 21, wherein the at least onecircuit protector comprises a fuse, the status element transmitting datarelated to operation of the fuse, the data comprising multiple bitsselected from the group comprising a unique radio identifier, amanufacturer serial number for the status element, a device type codefor the circuit protector, a location or address code for the circuitprotector, a power/control code, an equipment identification code, atesting code, a fault code, a customer code, a temperature code, avibration code, a displacement code, a mechanical stress code, amechanical strain code, an acoustical emission code, a noise code, athermal imagery code, an electrical resistance code, a pressure code, ahumidity code and a video code.
 30. A circuit protector systemcomprising: a plurality of overcurrent protection fuses, each of theovercurrent protection fuses having a primary fuse element extendingbetween first and second terminal elements, the primary fuse elementsdefining an interruptible current path therethrough upon an occurrenceof specified current conditions through the primary fuse element; astatus element associated with each of the circuit protectors, thestatus elements comprising monitoring modules adapted to sense a voltagedifferential across the first and second terminal elements of therespective fuses, and at least one communications module comprising alow power radio frequency (RF) transmitter, the communications moduleadapted to generate an RF data signal when a voltage drop across thefirst and second terminal elements is sensed; a plurality of radiorepeater/router elements adapted to forward RF data signals from any ofthe status elements to an intelligent gateway device; the gateway deviceadapted to receive data signals forwarded through the repeater/routerelements; and an overview and response dispatch system in communicationwith the gateway device, wherein the overview and response dispatchsystem is adapted to alert and summon responsible personnel of one ormore operated fuses, and identify the locations of the operated fusesfor replacement to efficiently re-energize affected circuitry.
 31. Thesystem of claim 30, wherein the data signal comprises a digital radiofrequency signal.
 32. The system of claim 30, wherein the monitoringmodules are mechanically and electrically connected to the first andsecond terminal elements of the respective fuses at a location exteriorto a body of the fuse, thereby providing retrofit installation to aninstalled fuse.
 33. The system of claim 30, wherein the gateway deviceprocesses the RF signal and converts received signals to a predeterminedmessage protocol that is different from a protocol of the RF signal. 34.The system of claim 30, wherein the management system is adapted toalert and summon personnel via at least one of an email notification, afax notification, a pager notification, a web page notification, and avoice notification.
 35. The system of claim 30, wherein the data signalcomprises multiple bits selected from the group comprising a uniqueradio identifier, a manufacturer serial number for the status element, adevice type code for the circuit protector, a location or address codefor the circuit protector, a power/control code, an equipmentidentification code, a testing code, a fault code, a customer code, atemperature code, a vibration code, a displacement code, a mechanicalstress code, a mechanical strain code, an acoustical emission code, anoise code, a thermal imagery code, an electrical resistance code, apressure code, a humidity code and a video code.
 36. The system of claim30, wherein the management system is adapted to await acknowledgement ofan alert to responsible personnel, and if no acknowledgment is receivedin a predetermined time period, re-alert and re-summon responsiblepersonnel of the operated fuses and identify the locations of theoperated fuses.
 37. The system of claim 30, wherein the electronicmanagement system is adapted to initiate special procedures in responseto operation of the circuit protectors, the special procedures selectedfrom the group of activating auxiliary power, shutting down equipment,and saving circuit data for analysis.
 38. A method of efficientlyre-energizing affected circuitry in an electrical system when a circuitprotector operates to isolate one portion of an electrical system fromanother portion of the electrical system, the method comprising:providing a status element proximate to the respective circuitprotectors of interest, and an electronic management system responsiveto the status elements; sensing, using the status elements, an operatingstate of the circuit protector when installed in the electrical system;and based upon the sensed state of the circuit protectors, communicatinga data signal from at least one of the status elements to a remotelocation when one of the circuit protectors has operated to isolate aportion of the electrical system, the data signal comprising at least anidentification code and an address code to identify the location of theoperated circuit protector.
 39. The method of claim 38, furthercomprising, in response to the communicated signals, generating an alertand summons from the electronic management system to responsiblepersonnel of the operated circuit protector and the location of theoperated circuit protector.
 40. The method of claim 38, furthercomprising, in response to the communicated signals, conveyinginformation regarding potential hazards in the location of the circuitprotector, and precautions to be utilized when responding to an operatedcircuit protector.
 41. The method of claim 38, wherein the circuitprotectors comprise fuses, the method further comprising communicatingwith at least one remote system relating to maintenance of theelectrical system, the at least one remote system being selected fromthe group of a circuit protector inventory management system toreplenish a depleted circuit protector inventory as inventory is used, acomputerized maintenance management system, a supervisory control anddata acquisition system, an industrial control and automation system, anenterprise resource planning system, an electronic data interchangesystem, a manufacturing resources planning system, and a supply chainmanagement system.
 42. The method of claim 38, wherein sensing anoperating state of the circuit protectors comprises sensing a voltagedrop across the circuit protectors.
 43. The method of claim 38, whereincommunicating a data signal from at least one of the status elementscomprises wirelessly transmitting the data signal.
 44. The method ofclaim 43, further comprising: providing a plurality of repeater/routersin the vicinity of the circuit protectors of interest, and anintelligent gateway device connected an overview and response dispatchsystem; receiving the communicated data signal from at least one of thestatus elements with one of the repeater/routers; forwarding, utilizingthe repeater/routers, the received signals to the gateway device; andprocessing, using the gateway device, signals received from therepeater/routers, before communicating with the management system. 45.The method of claim 38, further comprising generating an alert andsummons from the electronic management system via at least one of anemail notification, a fax notification, a pager notification, a web pagenotification, and a voice notification.
 46. The method of claim 38,wherein providing a status element proximate to the respective circuitprotectors of interest comprises attaching a sensing module to anexterior surface of the circuit protectors of interest, therebyfacilitating retrofit installation to existing fuses of an electricalsystem.
 47. A circuit protector system comprising: means for sensing anoperating state of a plurality of circuit protectors in an electricalsystem; means for communicating a data signal corresponding to a sensedoperation of one or more of the circuit protectors, thereby isolating atleast one portion of the electrical system from another portion of theelectrical system; means for receiving the data signal corresponding toa sensed operation of one or more of the circuit protectors; and meansfor generating an alert and summons to responsible personnel, withouthuman intervention, of the type and location of operated circuitprotectors to permit efficient re-energization of the circuitry.
 48. Thesystem of claim 47, wherein the means for communicating comprises meansfor transmitting a low power wireless signal.
 49. The system of claim47, wherein the means for receiving comprises an intelligent gatewaydevice element.
 50. The system of claim 47, wherein the means forgenerating an alert and summons comprises means for generating an alertand summons via at least one of an email notification, a faxnotification, a pager notification, a web page notification, and a voicenotification.
 51. The system of claim 47, wherein the circuit protectorscomprise fuses, the means for sensing an operating state comprisingmeans for attaching a voltage sensor to an exterior surface of the fuse.